U.S. patent application number 16/395376 was filed with the patent office on 2019-10-03 for compact containerized system and method for spray evaporation of water.
This patent application is currently assigned to Energy Water Solutions, LLC. The applicant listed for this patent is Energy Water Solutions, LLC. Invention is credited to Chuck Hanebuth, Stephen M. Shiner.
Application Number | 20190299114 16/395376 |
Document ID | / |
Family ID | 68056634 |
Filed Date | 2019-10-03 |
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United States Patent
Application |
20190299114 |
Kind Code |
A1 |
Shiner; Stephen M. ; et
al. |
October 3, 2019 |
COMPACT CONTAINERIZED SYSTEM AND METHOD FOR SPRAY EVAPORATION OF
WATER
Abstract
A wastewater evaporation system for spray evaporating water
comprising: a wastewater feed inlet; a pump, wherein an outlet of
the wastewater inlet is fluidly connected to an inlet of the pump
and wherein an outlet of the pump is fluidly connected to an inlet
of a manifold; a drip orifice, wherein an outlet of the manifold is
fluidly connected to an inlet of the drip orifice; a container,
wherein an upper portion of the container is enclosed with a
demister element; a packing system and/or a tray system disposed
within the container, wherein the outlet of the drip orifice
discharges water droplets onto the packing system and/or the tray
system; a discharge outlet, wherein a bottom of the container is
fluidly connected to the discharge outlet; and an air system
comprising an air blower and optionally an air preheater, wherein
the air system is disposed through a wall of the container and
wherein the air system discharges air flow counter to the water
droplets from the drip orifice. A method of spray evaporating water
while limiting emission of particles regulated as pollutants is
also disclosed.
Inventors: |
Shiner; Stephen M.; (Spring,
TX) ; Hanebuth; Chuck; (Spring, TX) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Energy Water Solutions, LLC |
Spring |
TX |
US |
|
|
Assignee: |
Energy Water Solutions, LLC
Spring
TX
|
Family ID: |
68056634 |
Appl. No.: |
16/395376 |
Filed: |
April 26, 2019 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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15177519 |
Jun 9, 2016 |
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16395376 |
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62173509 |
Jun 10, 2015 |
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
B01D 19/04 20130101;
C02F 2209/40 20130101; B01D 1/0082 20130101; C02F 2209/02 20130101;
C02F 2209/06 20130101; C02F 1/008 20130101; C02F 2303/12 20130101;
C02F 2303/26 20130101; C02F 1/50 20130101; C02F 2303/04 20130101;
C02F 1/048 20130101; C02F 1/66 20130101; B01D 1/16 20130101; C02F
1/042 20130101; C02F 1/12 20130101; C02F 2209/05 20130101; C02F
2303/22 20130101; C02F 2209/03 20130101; C02F 2209/008 20130101;
B01D 5/009 20130101; B01D 1/14 20130101; C02F 2209/38 20130101;
B01D 5/006 20130101; C02F 5/08 20130101; B01D 1/305 20130101; C02F
2201/005 20130101; B01D 1/20 20130101; C02F 2209/006 20130101; B05B
1/26 20130101 |
International
Class: |
B01D 1/14 20060101
B01D001/14; B01D 1/00 20060101 B01D001/00; B01D 1/20 20060101
B01D001/20; B01D 1/30 20060101 B01D001/30; B01D 19/04 20060101
B01D019/04; B05B 1/26 20060101 B05B001/26; C02F 1/00 20060101
C02F001/00; C02F 1/04 20060101 C02F001/04; C02F 1/12 20060101
C02F001/12; C02F 1/50 20060101 C02F001/50; C02F 1/66 20060101
C02F001/66; C02F 5/08 20060101 C02F005/08 |
Claims
1. A wastewater evaporation system for spray evaporating water
comprising: a. a wastewater feed inlet; b. a pump, wherein an
outlet of the wastewater inlet is fluidly connected to an inlet of
the pump and wherein an outlet of the pump is fluidly connected to
an inlet of a manifold; c. a drip orifice, wherein an outlet of the
manifold is fluidly connected to an inlet of the drip orifice; d. a
container, wherein an upper portion of the container is enclosed
with a demister element; e. a packing system and/or a tray system
disposed within the container, wherein the outlet of the drip
orifice discharges wastewater and/or water droplets onto the
packing system and/or tray system; f. a discharge outlet, wherein a
bottom of the container is fluidly connected to the discharge
outlet; and g. an air system comprising an air blower and,
optionally, an air preheater, wherein the air system is disposed
through a wall of the container and wherein the air system
discharges air flow counter to the wastewater and/or water droplets
from the drip orifice.
2. The system of claim 1, further comprising; a. a first valve,
wherein the wastewater feed inlet is fluidly connected to an inlet
of the first valve and an outlet of the first valve is fluidly
connected to the inlet of the pump; b. a second valve, wherein the
outlet of the pump is fluidly connected to an inlet of the second
valve and wherein an outlet of the second valve is fluidly
connected to the inlet of the manifold; c. a third valve, wherein
the bottom of the container is fluidly connected to an inlet of the
third valve and wherein an outlet of the third valve is fluidly
connected to the inlet of the pump; d. a fourth valve, wherein the
outlet of the pump is fluidly connected to an inlet of the fourth
valve and wherein an outlet of the fourth valve is fluidly
connected to the discharge outlet.
3. The system of claim 1, wherein the system is capable of
evaporating from about 30 to about 100 barrels of wastewater per
day.
4. The system of claim 1, wherein the pump produces a water flow
rate into the system from about 15 GPM to about 100 GPM.
5. The system of claim 1, wherein the demister element is from
about 4-inches to about 12-inches thick.
6. The system of claim 1, wherein the demister element is about
10-inches thick.
7. The system of claim 1, wherein the packing system and/or tray
system comprises random packing, structured packing, or
combinations thereof.
8. The system of claim 1, wherein the packing system and/or tray
system comprises a porous tray.
9. The system of claim 1, wherein the packing system comprises: a.
a porous tray; and b. a packing, wherein the packing is disposed on
the porous tray.
10. The system of claim 9, wherein the packing system comprises
random packing, structured packing, or combinations thereof.
11. The system of claim 9, wherein the packing is a random packing,
wherein the packing is made of ceramics, plastics, metals, or
combinations thereof.
12. The system of claim 9, wherein the packing is a structured
packing, wherein the packing is made of ceramics, plastics, metals,
or combinations thereof.
13. The system of claim 9, wherein the packing is a containerized
packing.
14. The system of claim 1, wherein the tray system comprises: a. a
first porous tray; and b. a second porous tray, wherein the first
porous tray discharges water droplets onto the second porous
tray.
15. The system of claim 1, wherein the air preheater comprises a
natural gas burner.
16. The system of claim 1, wherein the air preheater comprises a
natural gas burner, wherein the natural gas burner is adapted to be
moved relative to the packing system.
17. The system of claim 1, wherein the air preheater comprises a
natural gas burner and a natural gas powered electric
generator.
18. The system of claim 1, wherein the air preheater comprises a
natural gas burner and a natural gas control valve and wherein the
natural gas control valve is capable of providing fixed flow or
modulated flow.
19. The system of claim 1, wherein air flow from the air blower
disperses water droplets from the drip orifice.
20. The system of claim 1, wherein the air blower produces an air
flow rate from about 2,500 CFM to about 6,500 CFM.
21. The system of claim 1, wherein an air flow inlet of the air
preheater is fluidly connected to an air flow outlet of the air
blower.
22. The system of claim 1, wherein the air preheater produces an
air heating rate from about 0 million BTU per hour to about 2.1
million BTU per hour.
23. The system of claim 1, wherein the air preheater produces air
temperatures from about 50.degree. F. to about 400.degree. F.
24. The system of claim 1, wherein the air system is disposed
through the wall of the container upstream of the demister
element.
25. The system of claim 1, wherein the air system is disposed
through the wall of the container downstream of the demister
element.
26. The system of claim 1 further comprising a deflector or a
diffuser, wherein the deflector or diffuser is disposed within the
container to redirect air flow in the container.
27. The system of claim 1 further comprising a vane, wherein the
vane is disposed within the container to redirect the air flow in
the container.
28. The system of claim 27, wherein the vane extends across a
cross-section of the container.
29. The system of claim 1 further comprising a vane, wherein the
vane is disposed in an air duct between an air discharge outlet of
air system and an air inlet to the container.
30. The system of claim 1 further comprising a programmable logic
controller (PLC) or other computing device, wherein the PLC or
other computing device controls the air flow rate from the air
blower.
31. The system of claim 1 further comprising an acid conditioning
system, wherein the acid conditioning system adds an acid solution
to the wastewater.
32. The system of claim 1 further comprising a bactericide
conditioning system, wherein the bactericide conditioning system
adds bactericide to the wastewater.
33. The system of claim 1 further comprising a scale inhibition
conditioning system, wherein the scale inhibition conditioning
system adds scale inhibitor to the wastewater.
34. The system of claim 1 further comprising a defoamer system,
wherein the defoamer system adds defoamer to the wastewater.
35. The system of claim 1further comprising a skid, wherein the
wastewater evaporation system is mounted on the skid.
36. The system of claim 1 further comprising a skid mounted on or
removably secured to a trailer or a truck, wherein the wastewater
evaporation system is mounted on the skid.
37. The system of claim 1 further comprising a containment system,
wherein the containment system comprises a skid surrounded by a
liner and wherein the wastewater evaporation system is mounted on
the skid.
38. The system of claim 37 further comprising a draw line, wherein
an inlet of the draw line is disposed in the liner and an outlet of
the draw line is fluidly connected to an inlet of the
container.
39. The system of claim 37 further comprising a draw line, wherein
an inlet of the draw line is disposed in the liner and an outlet of
the draw line is fluidly connected to the inlet of the pump.
40. The system of claim 1 further comprising insulation and/or heat
tracing disposed around the pump.
41. The system of claim 2 further comprising insulation and/or heat
tracing disposed around the pump, the first valve, the second
valve, the third valve and the fourth valve.
42. The system of claim 1 further comprising a heated enclosure
disposed around the pump, optionally a lower portion of the
container, optionally an electric generator, and optionally a
nitrogen purge system.
43. The system of claim 1 further comprising an air, argon or
nitrogen purge system comprising an air, argon or nitrogen source,
wherein an outlet of the air, argon or nitrogen system is fluidly
connected to the inlet of the pump.
44. A method for spray evaporating water comprising: a. providing
the wastewater evaporation system of claim 1; b. selecting
predetermined parameters for a wastewater evaporation system for
spray evaporating water; c. drawing wastewater into the wastewater
evaporation system from an external water source using a pump; d.
diverting wastewater to a drip orifice; e. flowing the wastewater
through the drip orifice to create water droplets; f. flowing the
water droplets onto a packing system and/or tray system disposed
within a container of the wastewater evaporation system; g. blowing
air into the container counter to the water droplets from the drip
orifice using an air blower; h. collecting condensed water in a
bottom of the container; i. recycling the condensed water from the
bottom of the container, and j. diverting concentrated waste to the
discharge outlet.
45. The method of claim 44, further comprising monitoring
conductivity of condensed water using a conductivity meter.
46. The method of claim 44, wherein the predetermined parameters
comprise air flow rate, air heating rate, maximum conductivity, and
water flow rate, and wherein the concentrated water is discharged
to the discharge outlet when conductivity of the condensed water
reaches the maximum conductivity.
47. The method of claim 44, further comprising monitoring ambient
air temperature using a temperature sensor, wherein the
predetermined parameters further comprise minimum air
temperature.
48. The method of claim 47, wherein the system is shut down when
the ambient air temperature reaches the minimum air
temperature.
49. The method of claim 44 further comprising monitoring the pH of
the condensed water using a pH meter and adding acid solution to
the condensed water to maintain the pH at about 6.5 or below.
50. The method of claim 44 further comprising adding bactericide to
the condensed water.
51. The method of claim 44 further comprising adding scale
inhibitor to the condensed water.
52. The method of claim 44 further comprising adding defoamer to
the condensed water.
53. The method of claim 50 further comprising monitoring the pH of
the condensed water using a pH meter and adding acid solution to
the condensed water to maintain the pH at about 6.5 or below.
54. The method of claim 44 further comprising using a programmable
logic controller or other computing device to control the
system.
55. The method of claim 44, wherein the system is capable of
evaporating from about 30 to about 100 barrels of wastewater per
day.
56. The method of claim 44, wherein the pump produces a water flow
rate into the system from about 15 GPM to about 100 GPM.
57. The method of claim 44, wherein the demister element is about
4-inches to about 12-inches thick.
58. The method of claim 44, wherein the packing system and/or the
tray system comprises pall rings, random packing or combinations
thereof.
59. The method of claim 44, wherein the packing system and/or the
tray system comprises a porous tray.
60. The method of claim 44, wherein the packing system comprises:
a. a porous tray; and b. a packing, wherein the packing is disposed
on the porous tray.
61. The method of claim 60, wherein the packing is selected from
random packing, structured packing, and combinations thereof.
62. The method of claim 44, wherein the tray system comprises: a. a
first porous tray; and b. a second porous tray, wherein the first
porous tray discharges water droplets onto the second porous
tray.
63. The method of claim 44, wherein the air blower produces an air
flow rate from about 2,500 CFM to about 6,500 CFM.
64. The method of claim 44, wherein an air flow inlet of the air
preheater is fluidly connected to an air flow outlet of the air
blower.
65. The method of claim 44, wherein the air preheater produces an
air heating rate from about 0 million BTU per hour to about 2.1
million BTU per hour.
66. The method of claim 44, wherein the air preheater produces air
temperatures from about 50.degree. F. to about 400.degree. F.
67. The method of claim 44 further comprising pretreating
wastewater to reduce or remove volatile organic compounds upstream
of a wastewater inlet of the wastewater evaporation system.
68. The method of claim 44 further comprising discharging
evaporated water through the evaporated water outlet.
69. The method of claim 68 further comprising collecting the
evaporated water from the evaporated water outlet and condensing
the evaporated water in a low pressure conduit.
70. The method of claim 68 further comprising heating the
evaporated water upstream of the evaporated water outlet.
71. The method of claim 68 further comprising heating the
evaporated water downstream of the evaporated water outlet.
72. A wastewater evaporation system for spray evaporating water
comprising: a. a wastewater inlet; b. a pump, wherein an outlet of
the wastewater inlet is fluidly connected to an inlet of the pump
and wherein an outlet of the pump is fluidly connected to an inlet
of a manifold; c. a spray nozzle, wherein an outlet of the manifold
is fluidly connected to an inlet of the spray nozzle; d. a
horizontal container, wherein an upper portion of the container is
enclosed with a demister element and wherein the outlet of the
spray nozzle discharges water droplets into the container; e. a
discharge outlet, wherein a bottom of the container is fluidly
connected to the discharge outlet; f. an air system comprising an
air blower and optionally an air heater, wherein the air system is
disposed through a wall of the container and wherein the air system
discharges air flow counter to the water droplets from the spray
nozzle; and g. a deflector or a diffuser, wherein the deflector or
diffuser is disposed within the container to redirect air flow from
a center region of the container to a wall of the container.
73. The system of claim 72 further comprising a tapered insert,
wherein the tapered insert is disposed within the container to
redirect the air flow from the wall of the container to the center
region of the container.
74. The system of claim 72 further comprising a vane, wherein the
vane is disposed within the container to redirect the air flow in
the container.
75. The system of claim 74, wherein the vane extends across a
cross-section of the container.
Description
PRIOR RELATED APPLICATIONS
[0001] This application is a continuation-in-part of U.S.
Nonprovisional patent application Ser. No. 15/177,519, filed on
Jun. 9, 2016, which claims benefit of U.S. Provisional patent
application Ser. No. 62/173,509, filed on Jun. 10, 2015, entitled
"Containerized System and Method for Spray Evaporation of
Water."
FEDERALLY SPONSORED RESEARCH STATEMENT
[0002] Not Applicable (N/A)
REFERENCE TO MICROFICHE APPENDIX
[0003] N/A
FIELD OF INVENTION
[0004] The invention relates generally to spray evaporation of
water and, in particular, to a containerized system and method for
spray evaporation of water by controlling pump pressure and/or
water droplet size sprayed within a closed container by optimizing
air and water volumetric flow and droplet size sprayed within the
container.
BACKGROUND OF THE INVENTION
[0005] Current methods for evaporation of undesired water (e.g.,
landfill leachate, produced water, mining wastewater, and
wastewater) typically involve large surface area ponds, floating or
land-based atomizing sprayers which spray back into a pond, or
multi-stage flash evaporation (MSF). These methods have numerous
problems. The large surface area solar-evaporation or spray ponds
are slow to remove water, require large capital investments, and
pose a risk of leakage. The floating or land-based sprayers improve
the efficiency of the ponds but permit water droplets and
aerosolized dissolved solids (e.g., salts) to be carried by the
wind to contaminate other areas. MSF is a complex energy intensive
process with high resultant capital and operating costs as well as
problematic air emissions. The alternative to not evaporating the
water on or near the point of generation is removal via vacuum
truck. The vacuum trucks remove water from storage tanks or ponds
but require transportation for disposal or treatment of the
undesired water elsewhere. This can be quite expensive.
[0006] Therefore, there is a need for a compact containerized
system and method for spray evaporation of undesired water to speed
removal of the water, to contain the water droplets during
evaporation and to reduce the cost of water transportation and
disposal.
SUMMARY OF THE INVENTION
[0007] The invention relates generally to spray evaporation of
water and, in particular, to a compact containerized system and
method for efficient spray evaporation of water by controlling pump
pressure and/or water droplet size sprayed within a closed
container and by optimizing water volumetric flow and droplet size
sprayed within the container
[0008] The invention permits evaporation of large volumes of
undesired water within a containerized, mobile system, which
eliminates requirements for large evaporation ponds or vacuum truck
disposal. More specifically, the invention maximizes the
evaporation rate of undesired water by reducing water droplet size
sprayed within a closed container and by optimizing water droplet
size and volume sprayed within the container. The evaporated water
exits the container as water vapor through a mist arresting system,
leaving behind un-evaporated water droplets and dissolved minerals
to collect in the sump (bottom) of the container. The condensed
water is recirculated through the system and, once sufficiently
concentrated, the concentrated water is diverted to external waste
disposal storage.
[0009] A system for spray evaporating water comprises a wastewater
inlet; a pump, where an outlet of the wastewater inlet is fluidly
connected to an inlet of the pump and wherein an outlet of the pump
is fluidly connected to an inlet of a manifold; a spray nozzle,
wherein an outlet of the manifold is fluidly connected to an inlet
of the spray nozzle; a container, wherein upper and side portions
of the container are enclosed with a demister element and wherein
the outlet of the spray nozzle discharges into the container; and a
discharge outlet, wherein a bottom of the container is fluidly
connected to the discharge outlet.
[0010] In an embodiment, the pump produces a water flow rate from
about 50 gallons per minute (GPM) to about 800 GPM (and any range
or value there between). In an embodiment, the pump produces a
water flow rate from about 15 GPM to about 100 GPM.
[0011] A system for spray evaporating water comprising a wastewater
inlet comprises wastewater; a first valve, wherein an outlet of the
wastewater inlet is fluidly connected to an inlet of the first
valve; a first pump, wherein an outlet of the first valve is
fluidly connected to an inlet of the first pump; a container,
wherein upper and side portions of the container are enclosed with
a demister element and wherein the demister element retains
un-evaporated water inside the container; a spray nozzle, wherein
an outlet of the first pump is fluidly connected to a first inlet
of a manifold, wherein an outlet of the manifold is fluidly
connected to an inlet of the spray nozzle, and wherein an outlet of
the spray nozzle discharges into the container; a second pump,
wherein an outlet of the sump is fluidly connected to an inlet of
the second pump; a second valve; wherein an outlet of the second
pump is fluidly connected to a second inlet of a manifold and
wherein a first outlet of the manifold is fluidly connected to the
inlet of the spray nozzle; and a third valve, wherein a second
outlet of the manifold is fluidly connected to an inlet of the
third valve and wherein an outlet of the third valve is fluidly
connected to a discharge outlet.
[0012] In an embodiment, the system further comprises an air
blower, wherein air flow from the air blower disperses water
droplets from the spray nozzle. In an embodiment, the air blower is
disposed through a wall of the container such that air flow from
the air blower is counter to water droplets from the spray nozzle.
In an embodiment, the air blower is disposed through a wall of the
container such that air flow from the air blower is crossways to
water droplets from the spray nozzle. In an embodiment, the air
blower produces an air flow rate from about 60,000 cubic feet per
minute (CFM) to about 150,000 CFM (and any range or value there
between).
[0013] In an embodiment, the system further comprises an air
heater, wherein an air flow outlet of the air heater is fluidly
connected to an air flow inlet of the air blower.
[0014] In an embodiment, the spray system comprises a spray
manifold, wherein the outlet of the pump is fluidly connected to an
inlet of the spray manifold; and a spray nozzle, wherein an inlet
of the spray nozzle is connected to an outlet of the spray
manifold, and wherein an outlet of the spray nozzle discharges into
the container. In an embodiment, the spray nozzle is selected from
the group consisting of plain-orifice nozzles, shaped-orifice
nozzles, surface impingement spray nozzles, spiral spray nozzles,
and pressure swirl spray nozzles. In an embodiment, the spray
nozzle produces water droplet sizes from about 50 .mu.m to about
1,000 .mu.m (and any range or value there between).
[0015] In an embodiment, the system further comprises a
programmable logic controller (PLC) or other computing device,
wherein the PLC or other computing device controls the air flow
rate from the air blower and the water droplet size from the spray
nozzle.
[0016] In an embodiment, the system further comprises an acid
conditioning system, wherein the acid conditioning system adds an
acid solution to the wastewater.
[0017] In an embodiment, the system further comprises a bactericide
conditioning system, wherein the bactericide conditioning system
adds bactericide to the wastewater.
[0018] In an embodiment, the system further comprises a scale
inhibition conditioning system, wherein the scale inhibition
conditioning system adds scale inhibitor to the wastewater.
[0019] In an embodiment, the system further comprises a defoamer
system, wherein the defoamer system adds defoamer to the
wastewater.
[0020] In an embodiment, the first pump produces a water flow rate
from about 50 gallons per minute (GPM) to about 100 GPM (and any
range or value there between).
[0021] In an embodiment, the second pump produces a water flow rate
from about 500 GPM to about 800 GPM (and any range or value there
between).
[0022] In an embodiment, the demister element retains un-evaporated
water inside the container.
[0023] A wastewater evaporation system for spray evaporating water
comprises a wastewater inlet; a pump, wherein an outlet of the
wastewater inlet is fluidly connected to an inlet of the pump and
wherein an outlet of the pump is fluidly connected to an inlet of a
manifold; a spray nozzle, wherein an outlet of the manifold is
fluidly connected to an inlet of the spray nozzle; a horizontal
container, wherein an upper portion of the container is enclosed
with a demister element and wherein the outlet of the spray nozzle
discharges water droplets into the container; a discharge outlet,
wherein a bottom of the container is fluidly connected to the
discharge outlet; an air system comprising an air blower and
optionally an air heater, wherein the air system is disposed
through a wall of the container and wherein the air system
discharges air flow counter to the water droplets from the spray
nozzle; and a deflector or a diffuser, wherein the deflector or
diffuser is disposed within the container to redirect air flow from
a center region of the container to a wall of the container.
[0024] In an embodiment, the system further comprises a tapered
insert, wherein the tapered insert is disposed within the container
to redirect the air flow from the wall of the container to the
center region of the container.
[0025] In an embodiment, the system further comprises a vane,
wherein the vane is disposed within the container to redirect the
air flow in the container. In an embodiment, the vane extends
across a cross-section of the container.
[0026] A wastewater evaporation system for spray evaporating water
comprises a wastewater feed inlet; a pump, wherein an outlet of the
wastewater inlet is fluidly connected to an inlet of the pump and
wherein an outlet of the pump is fluidly connected to an inlet of a
manifold; a drip orifice, wherein an outlet of the manifold is
fluidly connected to an inlet of the drip orifice; a container,
wherein an upper portion of the container is enclosed with a
demister element; a packing system and/or a tray system disposed
within the container, wherein the outlet of the drip orifice
discharges water droplets onto the packing system and/or the tray
system; a discharge outlet, wherein a bottom of the container is
fluidly connected to the discharge outlet; and an air system
comprising an air blower and optionally an air preheater, wherein
the air system is disposed through a wall of the container and
wherein the air system discharges air flow counter to the water
droplets from the drip orifice.
[0027] In an embodiment, the system is capable of evaporating from
about 30 to about 1000 barrels of wastewater per day. In an
embodiment, the system is capable of evaporating from about 30 to
about 60 barrels of wastewater per day.
[0028] In an embodiment, the pump produces a water flow rate into
the system from about 15 GPM to about 100 GPM.
[0029] In an embodiment, the demister element is from about
4-inches to about 12-inches thick. In an embodiment, the demister
element is about 10-inches thick.
[0030] In an embodiment, the packing system and/or the tray system
comprises random packing, structured packing, or combinations
thereof. In an embodiment, the packing system and/or tray system
comprises containerized packing. In an embodiment, the packing
system and/or tray system comprises pall rings.
[0031] In an embodiment, the packing is made from different
materials (e.g., ceramics, plastics, stainless steel) to improve
performance at high temperatures.
[0032] In an embodiment, the packing system and/or the tray system
comprises a porous tray.
[0033] In an embodiment, the packing system comprises: a porous
tray; and a packing, wherein the packing is disposed on the porous
tray. In an embodiment, the packing is selected from random
packing, structured packing, and combinations thereof. In an
embodiment, the packing is random packing. In an embodiment, the
packing is structured packing. In an embodiment, the packing is
containerized packing. In an embodiment, the packing is pall
rings.
[0034] In an embodiment, the packing is made from different
materials (e.g., ceramics, plastics, stainless steel) to improve
performance at high temperatures.
[0035] In an embodiment, the tray system comprises: a first porous
tray; and a second porous tray, wherein the first porous tray
discharges water droplets onto the second porous tray.
[0036] In an embodiment, the air preheater comprises a natural gas
burner. In an embodiment, the air preheater comprises a natural gas
burner, wherein the natural gas burner is adapted to be moved
relative to the drip orifice.
[0037] In an embodiment, the air preheater comprises a natural gas
burner and a natural gas powered electric generator.
[0038] In an embodiment, the air preheater comprises a natural gas
burner and a natural gas control valve, wherein the natural gas
control valve is capable of providing fixed flow or modulated
flow.
[0039] In an embodiment, air flow from the air blower disperses
wastewater and/or water droplets from the drip orifice.
[0040] In an embodiment, the air blower produces an air flow rate
from about 2,500 CFM to about 6,500 CFM.
[0041] In an embodiment, an air flow inlet of the air preheater is
fluidly connected to an air flow outlet of the air blower.
[0042] In an embodiment, the air preheater produces an air heating
rate from about 0 million BTU per hour to about 2.1 million BTU per
hour.
[0043] In an embodiment, the air preheater produces air
temperatures from about 50.degree. F. to about 400.degree. F.
[0044] In an embodiment, the air system is disposed through the
wall of the container upstream of the demister element.
[0045] In an embodiment, the air system is disposed through the
wall of the container downstream of the demister element.
[0046] In an embodiment, the system further comprises a deflector
or a diffuser, wherein the deflector or diffuser is disposed within
the container to redirect air flow in the container.
[0047] In an embodiment, the system further comprises a vane,
wherein the vane is disposed within the container to redirect the
air flow in the container. In an embodiment, the vane extends
across a cross-section of the container.
[0048] In an embodiment, the system further comprises a vane,
wherein the vane is disposed in an air duct between an air
discharge outlet of air system and an air inlet to the
container.
[0049] In an embodiment, the system further comprises a
programmable logic controller (PLC) or other computing device,
wherein the PLC or other computing device controls the air flow
rate from the air blower.
[0050] In an embodiment, the system further comprises an acid
conditioning system, wherein the acid conditioning system adds an
acid solution to the wastewater.
[0051] In an embodiment, the system further comprising a
bactericide conditioning system, wherein the bactericide
conditioning system adds bactericide to the wastewater.
[0052] In an embodiment, the system further comprises a scale
inhibition conditioning system, wherein the scale inhibition
conditioning system adds scale inhibitor to the wastewater.
[0053] In an embodiment, the system further comprises a defoamer
system, wherein the defoamer system adds defoamer to the
wastewater.
[0054] In an embodiment, the system further comprises a skid,
wherein the wastewater evaporation system is mounted on the
skid.
[0055] In an embodiment, the system further comprises a skid
mounted on or removably secured to a trailer or a truck, wherein
the wastewater evaporation system is mounted on the skid.
[0056] In an embodiment, the system further comprises a containment
system, wherein the containment system comprises a skid surrounded
by a liner and wherein the wastewater evaporation system is mounted
on the skid. In an embodiment, the system further comprises a draw
line, wherein an inlet of the draw line is disposed in the liner
and an outlet of the draw line is fluidly connected to an inlet of
the container. In an embodiment, the system further comprises a
draw line, wherein an inlet of the draw line is disposed in the
liner and an outlet of the draw line is fluidly connected to the
inlet of the pump.
[0057] In an embodiment, the system further comprises insulation
and/or heat tracing disposed around the pump. In an embodiment, the
system further comprises insulation and/or heat tracing around the
pump, the first valve, the second valve, the third valve and the
fourth valve.
[0058] In an embodiment, the system further comprises a heated
enclosure disposed around the pump.
[0059] In an embodiment, the system further comprises an air, argon
or nitrogen purge system comprising an air, argon or nitrogen
source, wherein an outlet of the air, argon or nitrogen system is
fluidly connected to the inlet of the pump.
[0060] A method for spray evaporating water comprises selecting
predetermined parameters for a system for spray evaporating water;
drawing wastewater into the system from an external water source
using a pump; diverting wastewater to a spray nozzle; spraying the
wastewater through the spray nozzle to create water droplets;
dispersing the water droplets into a container of the system;
collecting condensed water in the sump of the container; recycling
the condensed water from the sump of the container, and diverting
concentrated waste to a waste outlet.
[0061] In an embodiment, the method further comprises monitoring
conductivity of condensed water using a conductivity meter.
[0062] In an embodiment, the predetermined parameters comprise air
flow rate, air heating rate, maximum conductivity, and water flow
rate, and wherein the concentrated water is discharged to the waste
outlet when conductivity of the condensed water reaches the maximum
conductivity.
[0063] In an embodiment, the air flow rate is from about 60,000 CFM
to about 150,000 CFM (and any range or value there between).
[0064] In an embodiment, the pump produces a water flow rate from
about 50 GPM to about 800 GPM (and any range or value there
between). In an embodiment, the pump produces a water flow rate
from about 15 GPM to about 100 GPM.
[0065] In an embodiment, the water droplet size is from 50 .mu.m to
about 1,000 .mu.m (and any range or value there between).
[0066] In an embodiment, the method further comprises monitoring
ambient air temperature using a temperature sensor, wherein the
predetermined parameters further comprise minimum air temperature.
In an embodiment, the system is shut down when the ambient air
temperature reaches the minimum air temperature.
[0067] In an embodiment, the method further comprises monitoring
the pH of the condensed water using a pH meter and adding acid
solution to the condensed water to maintain the pH at about 6.5 or
below, if required, based on waste water quality.
[0068] In an embodiment, the method further comprises adding
bactericide to the condensed water.
[0069] In an embodiment, the method further comprises adding scale
inhibitor to the condensed water. In an embodiment, the method
further comprising monitoring the pH of the condensed water using a
pH meter and adding acid solution to the condensed water to
maintain the pH at about 6.5 or below, if required, based on waste
water quality.
[0070] In an embodiment, the method further comprises adding
defoamer to the condensed water.
[0071] In an embodiment, the method further comprises using a
programmable logic controller or other computing device to control
the system.
[0072] A method for spray evaporating water comprising: providing a
wastewater evaporation system as discussed herein; selecting
predetermined parameters for the system; drawing wastewater into
the system from an external water source using a pump; diverting
wastewater to a drip orifice; flowing the wastewater through the
drip orifice to create water droplets; flowing the water droplets
onto a packing system and/or a tray system disposed within a
container of the system; blowing air into the container counter to
the water droplets from the drip orifice using an air blower;
collecting condensed water in a bottom of the container; recycling
the condensed water from the bottom of the container, and diverting
concentrated waste to a discharge outlet.
[0073] In an embodiment, the method further comprises monitoring
conductivity of condensed water using a conductivity meter.
[0074] In an embodiment, the predetermined parameters comprise air
flow rate, air heating rate, maximum conductivity, and water flow
rate, and wherein the concentrated water is discharged to the
discharge outlet when conductivity of the condensed water reaches
the maximum conductivity.
[0075] In an embodiment, the method further comprises monitoring
ambient air temperature using a temperature sensor, wherein the
predetermined parameters further comprise minimum air temperature.
In an embodiment, the system is shut down when the ambient air
temperature reaches the minimum air temperature.
[0076] In an embodiment, the method further comprises monitoring
the pH of the condensed water using a pH meter and adding acid
solution to the condensed water to maintain the pH at about 6.5 or
below.
[0077] In an embodiment, the method further comprises adding
bactericide to the condensed water.
[0078] In an embodiment, the method further comprises adding scale
inhibitor to the condensed water. In an embodiment, the method
further comprises monitoring the pH of the condensed water using a
pH meter and adding acid solution to the condensed water to
maintain the pH at about 6.5 or below.
[0079] In an embodiment, the method further comprises adding
defoamer to the condensed water.
[0080] In an embodiment, the method further comprises using a
programmable logic controller or other computing device to control
the system.
[0081] In an embodiment, the method further comprises pretreating
wastewater to reduce or remove volatile organic compounds upstream
of a wastewater inlet of the system.
[0082] In an embodiment, the method further comprises discharging
evaporated water through the evaporated water outlet. In an
embodiment, the method further comprises collecting the evaporated
water from the evaporated water outlet and condensing the
evaporated water in a low pressure conduit.
[0083] In an embodiment, the method further comprises discharging
evaporated water through the evaporated water outlet. In an
embodiment, the method further comprises further comprising heating
the evaporated water upstream of the evaporated water outlet.
[0084] In an embodiment, the method further comprises discharging
evaporated water through the evaporated water outlet. In an
embodiment, the method further comprises heating the evaporated
water downstream of the evaporated water outlet.
[0085] These and other objects, features and advantages will become
apparent as reference is made to the following detailed
description, preferred embodiments, and examples, given for the
purpose of disclosure, and taken in conjunction with the
accompanying drawings and appended claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0086] For a further understanding of the nature and objects of the
present invention, reference should be made to the following
detailed disclosure, taken in conjunction with the accompanying
drawings, in which like parts are given like reference numerals,
and wherein:
[0087] FIG. 1A illustrates a schematic of an exemplary system for
spray evaporation of water according to an embodiment of the
present invention;
[0088] FIG. 1B illustrates a schematic of a front view of the
exemplary system of FIG. 1A;
[0089] FIG. 1C illustrates a schematic of a rear view of the
exemplary system of FIG. 1A;
[0090] FIG. 2A illustrates a drawing of a front view of an
exemplary system for spray evaporation of water according to an
embodiment of the present invention;
[0091] FIG. 2B illustrates a drawing of a front, left perspective
view of the exemplary system in FIG. 2A;
[0092] FIG. 2C illustrates a drawing of a front, right perspective
view of the exemplary system in FIG. 2A;
[0093] FIG. 2D illustrates a drawing of a front, left perspective
view of an exemplary system for spray evaporation of water
according to an embodiment of the present invention;
[0094] FIG. 2E illustrates a drawing of a left side view of an
exemplary system for spray evaporation of water according to an
embodiment of the present invention;
[0095] FIG. 2F illustrates a drawing of a rear view of an exemplary
system for spray evaporation of water according to an embodiment of
the present invention;
[0096] FIG. 3 illustrates a drawing of a front, left perspective
view of an exemplary system for spray evaporation of water
according to an embodiment of the present invention, showing an
internal spray system;
[0097] FIG. 4A illustrates a schematic of an exemplary system for
spray evaporation of water according to an embodiment of the
present invention;
[0098] FIG. 4B illustrates a schematic of a front portion of the
exemplary system of FIG. 4A;
[0099] FIG. 4C illustrates a schematic of a rear portion of the
exemplary system of FIG. 4A;
[0100] FIG. 5A illustrates a drawing of a front, left perspective
view of an exemplary system for spray evaporation of water
according to an embodiment of the present invention, showing inlet,
recycle and discharge piping;
[0101] FIG. 5B illustrates a drawing of a front, left perspective
view of an exemplary system for spray evaporation of water
according to an embodiment of the present invention, showing
hydraulic air blowers with hydraulic drive system and
reservoir;
[0102] FIG. 5C illustrates a drawing of a front, left perspective
view of an exemplary system for spray evaporation of water
according to an embodiment of the present invention, showing an air
ducting plenum to force blower inlet air through heaters;
[0103] FIG. 5D illustrates a drawing of an upper, left perspective
view of an exemplary system for spray evaporation of water
according to an embodiment of the present invention, showing
optional catwalks and ladders to access demister system;
[0104] FIG. 6 illustrates a block diagram for a programmable logic
controller (PLC) or computing device for an exemplary system for
spray evaporation of water according to an embodiment of the
present invention;
[0105] FIG. 7A illustrates a method of using an exemplary system
for spray evaporation of water according to an embodiment of the
present invention;
[0106] FIG. 7B illustrates additional, optional steps for the
method of FIG. 7A;
[0107] FIG. 8A illustrates a method of using an exemplary system
for spray evaporation of water according to an embodiment of the
present invention;
[0108] FIG. 8B illustrates additional, optional steps for the
method of FIG. 8A;
[0109] FIG. 9 illustrates a flow diagram for a PLC or computing
device for an exemplary system for spray evaporation of water
according to an embodiment of the present invention;
[0110] FIG. 10A illustrates a schematic of an exemplary system for
spray evaporation of water according to an embodiment of the
present invention;
[0111] FIG. 10B illustrates a schematic of a front view of the
exemplary system of FIG. 10A;
[0112] FIG. 10C illustrates a schematic of a rear and downstream
view of the exemplary system of FIGS. 10A-10B;
[0113] FIG. 11A illustrates a drawing of an upper view of an
exemplary system for spray evaporation of water according to an
embodiment of the present invention;
[0114] FIG. 11B illustrates a drawing of a left side view of the
exemplary system of FIG. 11A;
[0115] FIG. 11C illustrates a drawing of front view of the
exemplary system of FIGS. 11A-11B;
[0116] FIG. 11D illustrates a drawing of a rear view of the
exemplary system of FIGS. 11A-11C;
[0117] FIG. 11E illustrates a drawing of a rear, right upper
perspective view of the exemplary system of FIGS. 11A-11D;
[0118] FIG. 11F illustrates a drawing of a rear, left upper
perspective view of the exemplary system of FIGS. 11A-11E;
[0119] FIG. 12A illustrates a method of using an exemplary system
for spray evaporation of water according to an embodiment of the
present invention; and
[0120] FIG. 12B illustrates additional, optional steps for the
method of FIG. 12A.
DETAILED DESCRIPTION OF EMBODIMENTS OF THE INVENTION
[0121] The following detailed description of various embodiments of
the present invention references the accompanying drawings, which
illustrate specific embodiments in which the invention can be
practiced. While the illustrative embodiments of the invention have
been described with particularity, it will be understood that
various other modifications will be apparent to and can be readily
made by those skilled in the art without departing from the spirit
and scope of the invention. Accordingly, it is not intended that
the scope of the claims appended hereto be limited to the examples
and descriptions set forth herein but rather that the claims be
construed as encompassing all the features of patentable novelty
which reside in the present invention, including all features which
would be treated as equivalents thereof by those skilled in the art
to which the invention pertains. Therefore, the scope of the
present invention is defined only by the appended claims, along
with the full scope of equivalents to which such claims are
entitled.
System for Spray Evaporation of Water
[0122] A schematic of an exemplary alternative system 100, 200, 300
for spray evaporation of water according to an embodiment of the
present invention is shown in FIGS. 1A-3. The system 100, 200, 300
comprises a wastewater inlet 104, 204, a first (feed) pump 118,
218, a first manifold 128, 228, a spray system 136, 236, 336, a
container 139, 239, 339, a demister element 145, 245, 345, an air
blower 142, 242 and a discharge outlet 176, 276.
[0123] In an embodiment, the system 100, 200, 300 is capable of
evaporating between about 2,000 to about 10,000 gallons of
wastewater per day (see FIGS. 1A-3). If a higher throughput is
desired, a plurality of the system 100, 200, 300 may be used in
parallel to treat the wastewater.
Inlet System
[0124] In an embodiment, the system 100, 200 may further comprise a
first (feed) shut-off valve 106, 206 and/or a first (feed) valve
112, 212. The wastewater inlet 104 may be connected to an inlet of
a first shut-off valve 106 via a pipe 108. An outlet of the first
shut-off valve 106 may be connected to an inlet of the pump 118 via
a pipe 116
[0125] The wastewater inlet 104 may be any suitable wastewater
inlet that can handle up to about 40 psi. Suitable wastewater
inlets include, but are not limited to, flange connections,
cam-lock fittings and hammer unions. In an embodiment, the
wastewater inlet 104 is a flange connection (see FIGS. 1A-3). The
wastewater inlet 104 permits connection to an external wastewater
source via a wastewater suction header 102. The water inlet 104 may
be connected to the external wastewater source via a hose, pipe or
other means customary in the art.
[0126] In an embodiment, the system 100, 200 may further comprise a
first (feed) valve 112, 212. The first (feed) valve 112 may be any
suitable switching valve. Suitable first (feed) valves 112 include,
but are not limited to, ball valves. For example, a suitable first
(feed) valve 112 is available from GF Piping Systems. In an
embodiment, the first (feed) valve 112 may be a GF Piping System
Type 546 Electric Actuated Ball Valve from GF Piping Systems. In an
embodiment, the first (feed) valve 112 may be automatic or manual.
In an embodiment, the first (feed) valve 112 may be electric or
pneumatic actuation. In an embodiment, the first (feed) valve 112
may be normally CLOSED.
[0127] In an embodiment, the system 100 may further comprise a
first limit switch 113 and a second limit switch 114. In an
embodiment, the first limit switch 113 confirms that the first
(feed) valve 112 is OPEN; and the second limit switch 114 confirms
that the first (feed) valve 112 is CLOSED.
[0128] In an embodiment, the first (feed) valve 112 may have 2-inch
connections.
[0129] In an embodiment, the system 100, 200, 300 may further
comprise a first (feed) shut-off valve 106, 206, 306. The first
(feed) shut-off valve 106 may be any suitable shut-off valve.
Suitable first (feed) shut-off valves 106 include, but are not
limited to, ball valves and butterfly valves. For example, a
suitable first (feed) shut-off valve 106 is available from GF
Piping Systems. In an embodiment, the first (feed) shut-off valve
106 may be a GF Piping Systems Type 546 Ball Valve from GF Piping
Systems. In an embodiment, the first (feed) shut-off valve 106 may
be automatic or manual. In an embodiment, the first (feed) shut-off
valve 106 may be normally CLOSED.
[0130] In an embodiment, the first (feed) shut-off valve 106 may
have 2-inch connections.
[0131] The first (feed) shut-off valve 106 may be made of any
suitable corrosion-resistant material. The first (feed) shut-off
valve 106 may be made of any suitable corrosion-resistant metals or
plastics. Suitable metals include, but are not limited to,
plastic-coated carbon steel, stainless steel, Hastelloy.RTM. alloy,
Monel.RTM. alloy and combinations thereof; and suitable plastic
include, but are not limited to, polyvinylchloride (PVC) polymers,
chlorinated polyvinyl chloride (CPVC) polymers, fiberglass
reinforced plastic (FRP), Kynar.RTM. polyvinylidene fluoride (PVDF)
polymers, polyethylene polymers, polypropylene polymers,
Teflon.RTM. perfluoroalkoxy (PFA) polymers, Teflon.RTM.
polytetrafluroethylene (PTFE) polymers, and combinations thereof.
In an embodiment, the first (feed) shut-off valve 106 (wetted
components) may be made of polyvinyl chloride (PVC) and ethylene
propylene diene monomer (EPDM) rubber.
[0132] An outlet of the first (feed) shut-off valve 106 may be
connected to an inlet of the first (feed) valve 112 via pipe 108.
An outlet of the first (feed) valve 112 may be connected to an
inlet of a first (feed) pump 118 via a pipe 116.
[0133] The pipe 108, 116 may be made of any suitable
corrosion-resistant pipe. The pipe 108, 116 may be any suitable
corrosion-resistant metals or plastics. Suitable metals include,
but are not limited to, plastic-coated carbon steel, stainless
steel, super-duplex stainless steel, AL-6XN alloy, Ni-Al-Brz alloy,
Hastelloy.RTM. alloy, Monel.RTM. alloy and combinations thereof and
suitable plastics include, but are not limited to, chlorinated
polyvinyl chloride (CPVC) polymers, fiberglass reinforced plastic
(FRP), Kynar.RTM. polyvinylidene fluoride (PVDF) polymers,
polyethylene polymers, polypropylene polymers, polyvinyl chloride
(PVC) polymers, Teflon.RTM. perfluoroalkoxy (PFA) polymers,
Teflon.RTM. polytetrafluroethylene (PTFE) polymers, and
combinations thereof. In an embodiment, the pipe 108, 116 may be
made of plastic-coated carbon steel. In an embodiment, the pipe
108, 116 may be made of Plasite 7159 HAR-coated carbon steel. In an
embodiment, the pipe 108, 116 may be made of 316 stainless
steel.
[0134] In an embodiment, the pipe 108, 116 may be 2-inch pipe.
[0135] The first (feed) pump 118 may be any suitable pump. Suitable
first (feed) pumps 118 include, but are not limited to, centrifugal
pumps. For example, a suitable first (feed) pump 118 is available
from MP Pumps Inc. In an embodiment, the first (feed) pump 118 may
be a FLOMAX.RTM. 8 Self-Priming Centrifugal Pump from MP Pumps Inc.
In an embodiment, the first (feed) pump 118 may be about 3 to about
5 HP centrifugal pump.
[0136] In an embodiment, the first (feed) pump 118 may have 2-inch
connections.
[0137] The first (feed) pump 118 may be made of any suitable
corrosion-resistant material. The first (feed) pump 118 may be made
of any suitable corrosion-resistant metals or plastics. Suitable
metals include, but are not limited to, cast iron, stainless steel,
super-duplex stainless steel, AL-6XN alloy, Ni-Al-Brz alloy,
Hastelloy.RTM. alloy, Monel.RTM. alloy and combinations thereof and
suitable plastics include, but are not limited to, chlorinated
polyvinyl chloride (CPVC) polymers, fiberglass reinforced plastic
(FRP), Kynar.RTM. polyvinylidene fluoride (PVDF) polymers,
polyethylene polymers, polypropylene polymers, polyvinyl chloride
(PVC) polymers, Teflon.RTM. perfluoroalkoxy (PFA) polymers,
Teflon.RTM. polytetrafluroethylene (PTFE) polymers, and
combinations thereof. For example, the first (feed) pump 118
(wetted components) may be made of stainless steel, super-duplex
stainless steel, AL-6XN alloy, Ni-Al-Brz alloy, Hastelloy.RTM.
alloy, Monel.RTM. alloy or FRD. In an embodiment, the first (feed)
pump 118, including internal wetted components, was made of 316
stainless steel. In an embodiment, the first (feed) pump 118 may be
made of cast iron if a shorter service life is acceptable.
[0138] In an embodiment, the system 100, 200, 300 may further
comprise a basket strainer 124, 224 and an optional pressure sensor
(not shown). An inlet of the basket strainer 124 may be fluidly
connected to an outlet of pipe 120, and an outlet of the basket
strainer 124 may be fluidly connected to an inlet of pipe 126. The
basket strainer 124 retains debris in the water feed to prevent
clogging of the spray nozzles 138, 338. An obstruction in the
basket strainer 124 may be detected via a decreased feed rate at
the first flow meter 122.
[0139] The basket strainer 124 may be any suitable basket strainer,
and may contain a reusable or disposable mesh or synthetic fiber
bag. A suitable basket strainer 124 includes, but is not limited
to, 1/8-inch perforated baskets, contained within a simplex or
duplex housing. For example, a suitable basket strainer 124 is
available from Hayward or Rosedale. In an embodiment, the basket
strainer 124 may be a 1/8-inch perforated basket from Hayward or
Rosedale.
[0140] The basket strainer 124 may be made of any suitable
corrosion-resistant material. The basket strainer 124 may be made
of any suitable corrosion-resistant metals or plastics. The basket
strainer 124 may be any suitable metal or plastic basket strainer.
Suitable metals include, but are not limited to, stainless steel,
Hastelloy.RTM. alloy, Monel.RTM. alloy and combinations thereof;
and suitable plastics include, but are not limited to, chlorinated
polyvinyl chloride (CPVC) polymers, Kynar.RTM. polyvinylidene
fluoride (PVDF) polymers, polyvinyl chloride (PVC) polymers,
Teflon.RTM. perfluoroalkoxy (PFA) polymers, Teflon.RTM.
polytetrafluroethylene (PTFE) polymers, and combinations thereof.
In an embodiment, the basket strainer 124 (basket) may be made of
316 stainless steel.
[0141] In an embodiment, the optional pressure sensor (not shown)
may be fluidly connected to either the pipe 120 or the inlet of the
basket strainer 124. An obstruction in the basket strainer 124 may
also be detected via an increase in pressure at the optional
pressure sensor (not shown).
[0142] The optional pressure sensor (not shown) may be any suitable
pressure sensor. For example, a suitable pressure sensor is
available from Rosemount, Inc. In an embodiment, the pressure
sensor may be a Rosemount 2088 Absolute and Gage Pressure
Transmitter from Rosemount, Inc.
[0143] An outlet of the first (feed) pump 118 may be connected to
an inlet of a basket strainer 124 via pipe 120. An outlet of the
basket strainer 124 may be connected to a first inlet to a first
manifold 128 via a pipe 126.
[0144] The pipe 120, 126, 128 may be made of any suitable
corrosion-resistant pipe. The pipe 120, 126, 128 may be any
suitable metal or plastic pipe. Suitable metals include but are not
limited to, plastic-coated carbon steel, stainless steel,
super-duplex stainless steel,
[0145] AL-6XN alloy, Ni-Al-Brz alloy, Hastelloy.RTM. alloy,
Monel.RTM. alloy and combinations thereof; and suitable plastics
include, but are not limited to, chlorinated polyvinyl chloride
(CPVC) polymers, fiberglass reinforced plastic (FRP), Kynar.RTM.
polyvinylidene fluoride (PVDF) polymers, polyethylene polymers,
polypropylene polymers, polyvinyl chloride (PVC) polymers,
Teflon.RTM. perfluoroalkoxy (PFA) polymers, Teflon.RTM.
polytetrafluroethylene (PTFE) polymers, and combinations thereof.
In an embodiment, the pipe 120, 126, 128 may be made of
plastic-coated carbon steel. In an embodiment, the pipe 120, 126,
128 may be made of Plasite 7159 HAR-coated carbon steel. In an
embodiment, the pipe 120, 126, 128 may be made of 316 stainless
steel.
[0146] In an embodiment, the pipe 120, 126, 128 may be 2-inch
pipe.
[0147] An outlet of the first manifold 128 may be connected to an
inlet of a spray system 134, 334. In an embodiment, the spray
system 134, 334 comprises a spray manifold 136, 336 and a spray
nozzle 138, 338, wherein the spray nozzle 138, 338 may be connected
to an outlet of the spray manifold 136, 336. In an embodiment, the
spray system 134, 334 is disposed inside the container 139,
339.
[0148] An outlet of the spray nozzle 138, 338 discharges water
droplets inside the container 139, 339. An upper portion or top
side of the container 139, 339 is enclosed with the demister
element 145, 345 to retain the water droplets inside the container
139, 339. In an embodiment, a side portion of the container 139,
339 is also enclosed with the demister element 145, 345 to retain
the water droplets inside the container 139, 339. The demister
element 145, 345 is secured to and supported by the container 139,
339 in a manner customary in the art.
[0149] At least some of the water droplets evaporate to form water
vapor. The water vapor passes through the demister element 145, 345
and out the evaporated water outlet 146, 346. Any un-evaporated
water is retained by the demister element 145, 345 and falls to a
sump (bottom) of the container 139, 339.
[0150] In an embodiment, the spray system 134, 334 comprises a
spray manifold 136, 336 and a plurality of spray nozzles 138',
138'' wherein each of the plurality of spray nozzles 138', 138''
may be connected to an outlet of the spray manifold 136, 336.
Outlets of the plurality of spray nozzles 138', 138'' discharge
water droplets inside the container 139, 339. An upper portion or
top side of the container 139, 339 is enclosed with the plurality
of demister elements 145', 145'' to retain the water droplets
inside the container 139, 339. In an embodiment, a side portion of
the container 139, 339 is also enclosed with the demister element
145, 345 to retain the water droplets inside the container 139,
339. The plurality of demister elements 145', 145'' are secured to
and supported by the container 139, 339 in a manner customary in
the art.
[0151] At least some of the water droplets evaporate to form water
vapor. The water vapor passes through pores (tortuous paths) in the
plurality of demister elements 145', 145'' and out the evaporated
water outlet 146, 346. Any un-evaporated water is retained by the
plurality of demister elements 145', 145'' and falls to the sump
(bottom) of the container 139, 339.
[0152] The evaporated water outlet 146, 346 comprises a plurality
of outlet pores (not shown) in the plurality of demister elements
145', 145''.
[0153] The spray nozzle 138, 338 may be any suitable spray nozzle.
Suitable spray nozzles 138, 338 include, but are not limited to,
plain-orifice nozzles, shaped-orifice nozzles, surface impingement
spray nozzles, spiral spray nozzles, and pressure swirl spray
nozzles. For example, a suitable spray nozzle 138, 338 is available
from BETE Fog Nozzle, Inc. In an embodiment, the spray nozzle 138,
338 may be a Type TF spiral spray nozzle from BETE Fog Nozzle, Inc.
In an embodiment, the spiral spray nozzle 138, 338 may be 30, 60,
90, 120, 150 and 170 degrees. In an embodiment, the spiral spray
nozzle may be capable from about 50 gallons per minute (GPM) to
about 70 GPM per spray head (and any range or value there between).
In an embodiment, the rotary atomizer produces water droplet sizes
from about 50 .mu.m to about 1,000 .mu.m. In an embodiment, the
spray nozzles 138, 338 are positioned inside the container.
[0154] The spray nozzle 138, 338 may be made of any suitable
corrosion-resistant material. The spray nozzle 138, 338 may be made
of any suitable corrosion-resistant metals or plastics. Suitable
metals, include, but are not limited to, brass, Cobalt Alloy 6,
reaction bonded silicon carbide (RB SC) ceramic, stainless steel,
Hastelloy.RTM. alloy, Monel.RTM. alloy, and combinations thereof;
and suitable plastics, include, but are not limited to,
polypropylene, polytetrafluroethylene (PTFE), polyvinyl chloride
(PVC), and combinations thereof. In an embodiment, the spray nozzle
138, 338 (spray head) may be made of PVC. In an embodiment, the
spray nozzle 138, 338 (wetted component) may be made of PVC. In an
embodiment, the spray nozzle 138, 338 (wetted component) may be
made of Cobalt Alloy 6 and/or RB SC ceramic.
[0155] The container 139, 339 may be any suitable container. The
container 139, 339 may be mobile or it may be stationary. Suitable
containers 139, 339 include, but are not limited to, intermodal
containers and frac tanks (see FIGS. 2A-2F). For example, a
suitable frac tank container 139, 339 is available from PCI
Manufacturing, LLC. In an embodiment, the container 139, 339 may be
a 500BBL, V-bottom frac tank from PCI Manufacturing, LLC. For
example, a suitable intermodal container 139, 339 is available from
West Gulf Container Company. In an embodiment, the container 139,
339 may be a 40-foot high bay container from West Gulf Container
Company.
[0156] Alternatively, the container 139, 339 may be made of any
suitable corrosion-resistant material. The container 139, 339 may
be made of coated metal, corrosion-resistant metals or plastics.
Suitable coated metals include, but are not limited to,
epoxy-coated carbon steels, plastic-coated carbon steels, and
combinations thereof; suitable corrosion-resistant metals include,
but are not limited to, stainless steel, Hastelloy.RTM. alloy,
Monel.RTM. alloy, and combinations thereof; and suitable plastics
include, but are not limited to, polyethylene, polypropylene,
polyvinyl chloride (PVC), and combinations thereof. In an
embodiment, the container 139, 339 may be made of epoxy-coated
carbon steel and/or plastic-coated carbon steel. In an embodiment,
the container 139, 339 may be made of Plasite 7159 HAR-coated
carbon steel.
[0157] The container 139, 339 may be any suitable shape. Suitable
shapes include, but are not limited to, cylindrical, cubic, cuboid,
prism, pyramid, spherical and combinations thereof. In an
embodiment, the container 139, 339 may be approximately a cuboid
shape.
[0158] The demister element 145, 345 may be any suitable demister
element. Suitable demister elements 145, 345 include, but are not
limited to, crossflow cellular drift eliminators (see FIGS. 2A-2F).
For example, a suitable demister element 145, 345 is available from
Brentwood Industries, Inc. In an embodiment, the demister element
145, 345 may be an Accu-Pac.RTM. Crossflow Cellular Drift
Eliminator from Brentwood Industries, Inc.
[0159] Alternatively, the demister element 145, 345 may be made of
any suitable corrosion-resistant material. The demister element
145, 345 may be any suitable corrosion-resistant metals or
plastics. The demister element 145, 345 may be made of metal or
plastic mesh or baffled, torturous-path chevron-type plates.
Suitable metal mesh includes, but is not limited to, stainless
steel, Hastelloy.RTM. alloy, Monel.RTM. alloy and combinations
thereof; suitable plastic mesh includes, but are not limited to,
chlorinated polyvinyl chloride (CPVC) polymers, fiberglass
reinforced plastic (FRP), Kynar.RTM. polyvinylidene fluoride (PVDF)
polymers, polyethylene polymers, polypropylene polymers, polyvinyl
chloride (PVC) polymers, Teflon.RTM. perfluoroalkoxy (PFA)
polymers, Teflon.RTM. polytetrafluroethylene (PTFE) polymers, and
combinations thereof; and suitable chevron-type plates include, but
are not limited to, polyethylene, polypropylene, polyvinylchloride
(PVC), stainless steel, Teflon.RTM. perfluoroalkoxy (PFA) polymers,
Teflon.RTM. polytetrafluroethylene (PTFE) polymers. In an
embodiment, the demister element 145, 345 may be made of 316
stainless steel. In an embodiment, the demister element 145, 345
may be made of PVC.
[0160] The demister element 145, 345 may be any suitable shape to
enclose an upper portion and/or a side portion of the container
139, 339. Suitable shapes include, but are not limited to,
cylindrical, cubic, cuboid, prism, pyramid, spherical, and portions
and combinations thereof. In an embodiment, the demister element
145, 345 (e.g., upper portion and/or side portion) may be a cuboid
shape about 4-feet wide by about 8-feet long and about 4-inches to
about 6-inches thick.
[0161] As shown in FIG. 1, the demister element 145, 345 forms an
upper portion and a side portion of the cuboid shape of the
container 139, 339. In an embodiment, the demister element 145, 345
(e.g., upper portion) may be a cuboid shape about 8-feet wide by
about 16-feet long and from about 6-inches thick to about 12-inches
thick (and any range or value there between). In an embodiment, the
demister element 145, 345 (e.g., side portion) may be a cuboid
shape about 6-feet wide by about 8-feet long and from about
6-inches thick to about 12-inches thick (and any range or value
there between).
[0162] In an embodiment, the demister element 145, 345 (e.g., upper
portion) may be a cuboid shape about 8-feet wide by about 16-feet
long and about 6-inches thick. In an embodiment, the demister
element 145, 345 (e.g., side portion) may be a cuboid shape about
6-feet wide by about 8-feet long and about 6-inches thick.
[0163] The evaporated water outlet 146, 346 comprises a plurality
of outlet pores (not shown) in the demister element 145, 345.
[0164] In an embodiment, the system 100 may further comprise a
first sacrificial anode 197 and a second sacrificial anode 198 for
galvanic cathode (corrosion) protection of the container 139, 339.
The first sacrificial anode 197 and the second sacrificial anode
198 may be disposed in the sump (bottom) of the container 139,
339.
[0165] The first sacrificial anode 197 and the second sacrificial
anode 198 may be made of any suitable galvanic anode material. For
example, suitable galvanic anode materials include, but are not
limited to, aluminum, magnesium and zinc. In an embodiment, the
first sacrificial anode 197 and the second sacrificial anode 198
may be made of aluminum and/or zinc.
Air Blower and Heater System
[0166] In an embodiment, the system 100, 200, 300 may further
comprise an air blower 142, 242. In an embodiment, air flow from
the air blower 142 disperses the water droplets from the spray
nozzle 138, 338. In an embodiment, the air blower 142 is disposed
through a wall of the container 139, 339 such that air flow from
the air blower 142 is counter to the water droplets from the spray
nozzle 138, 338.
[0167] In an embodiment, the air blower 142 is disposed through a
wall of the container 139, 339 such that air flow from the air
blower 142 is crossways to the water droplets from the spray nozzle
138, 338. In an embodiment, a wastewater to air ratio may range
from about 550 gallons per minute (GPM)/about 150,000 cubic feet
per minute (CFM) to about 800 GPM/60,000 CFM (and any range or
value there between).
[0168] The air blower 142 may be any suitable axial blower. For
example, a suitable air blower 142 is available from L. C. Eldridge
Sales Co. In an embodiment, the air blower 142 may be a 95-inch
Eldridge Model IC92S-3GD310-R3A fan from L. C. Eldridge Sales Co.
In an embodiment, the air blower 142 may be a fixed or
variable-speed air blower. In an embodiment, the air blower 142 may
provide from about 60,000 CFM to about 150,000 CFM (and any range
or value there between). In an embodiment, the air blower 142 may
provide about 100,000 CFM.
[0169] In an embodiment, the system 100, 200, 300 may further
comprise an air blower and heater system 141, 241, 341. For
example, the air blower and heater system 141, 241, 341 may be
disposed through a rear wall of the container 139, 339 when the
spray nozzles 138', 138'' of the spray system 134, 334 discharge
toward the rear of the container 139, 339.
[0170] In an embodiment, the air blower and heater system 141, 241,
341 comprises an air blower 142 and an air heater 143. In an
embodiment, an air flow outlet of the air heater 143 is fluidly
connected to an air flow inlet of the air blower 142.
[0171] The air heater 143 may be any suitable heater. For example,
the air heater is available from Maxon Corporation. In an
embodiment, the air heater 143 may be a Maxon APX Line Burner
(natural gas burner) from Maxon Corporation. In an embodiment, the
air heater 143 may provide an air heating rate from about 0 million
BTU per hour to about 4 million BTU per hour (and any range or
value there between).
[0172] In an embodiment, the air heater 143 may have one or more
combustion air blower(s). In an embodiment, the combustion air
blower may be about 1.5 horsepower (HP).
Optional Air Deflector, Diffusers, Tapered Inserts and Vanes
[0173] When the hot air from the air blower and preheater 141 is
introduced into an air inlet of the container 139 (i.e.,
evaporation module), the air flow may not have an even distribution
across the container 139. Further, the water spray may not be
uniform in the container 139 and, as a result, the degree of
saturation in the air may be reduced. To improve the evaporation
rate, the air and water droplet mixing must be improved to assure
complete transfer of water from the liquid phase to the vapor
phase. One way to achieve this is to use a series of deflectors,
diffusers, tapered inserts and/or vanes to promote mixing.
[0174] In an embodiment, the system 100 may further comprise a
deflector and/or a diffuser, wherein the deflector and/or diffuser
may be disposed within the container 139.
[0175] The deflector and/or diffuser may be any suitable deflector
or diffuser capable of achieving the desired degree of mixing in
the container 139. For example, a suitable deflector or diffuser
includes, but is not limited to, a flat metal sheet, an inclined
metal sheet, a perforated metal sheet, a solid metal sheet, and
combinations thereof to create a mixing vane effect.
[0176] The deflector and/or diffuser may be any suitable size and
shape.
[0177] In an embodiment, the size and location of the deflector
and/or diffuser may be adjusted to achieve optimal performance
based on air temperature, altitude, humidity, and other factors. In
an embodiment, the deflectors and/or diffusers are located to
redirect the air flow from the center of the container 139 to the
walls of the container 139.
[0178] In an embodiment, the deflector and/or diffuser may be
mounted in the container 139 to allow adjustments during operation
to achieve optimal performance based on air temperature, altitude,
humidity, and other factors.
[0179] In an embodiment, the system 100 further comprises a tapered
insert, wherein the tapered may be disposed within the container
139.
[0180] The tapered insert may be any suitable tapered insert
capable of achieving the desired degree of mixing in the container
139. For example, a suitable tapered insert includes, but is not
limited to, a flat metal sheet, an inclined metal sheet, a
perforated metal sheet, a solid metal sheet, and combinations
thereof to create a mixing vane effect.
[0181] The tapered insert may be any suitable size and shape.
[0182] In an embodiment, the size and location of the tapered
insert may be adjusted to achieve optimal performance based on air
temperature, altitude, humidity, and other factors. In an
embodiment, the tapered insert may be located to redirect the air
flow from the walls of the container 139 to the center of the
container 139.
[0183] In an embodiment, the tapered insert may be mounted in the
container 139 to allow adjustments during operation to achieve
optimal performance based on air temperature, altitude, humidity,
and other factors.
[0184] In an embodiment, the system 100 further comprises a vane,
wherein the vane may be disposed within the container 139.
[0185] The vane may be any suitable vane capable of achieving the
desired degree of mixing in the container 139. For example, a
suitable vane includes, but are not limited to, a metal and/or wood
flat sheet, an inclined metal and/or wood sheet, a perforated metal
and/or wood sheet, a solid metal and/or wood sheet, and
combinations thereof to create a mixing vane effect.
[0186] The vane may be any suitable size and shape.
[0187] In an embodiment, the size and location of the vane may be
adjusted to achieve optimal performance based on air temperature,
altitude, humidity, and other factors. In an embodiment, the vane
extends across a cross-section (e.g., diameter) of the container
139.
Recycle System
[0188] In an embodiment, the system 100, 200 may further comprise a
second (recycle) shut-off valve 153, 253, a second (recycle) pump
156, 256 and a second (recycle) valve 166, 266. An outlet of the
sump (bottom) of the container 139, 339 may be connected to an
inlet of a second (recycle) pump 156 via pipe 154. An outlet of the
second (recycle) pump 156 may be connected to an inlet of a second
manifold 162 via a pipe 158. A first outlet of the second manifold
162 may be connected to a second (recycle) valve 166 discussed
below.
[0189] In an embodiment, the system 100, 200 may further comprise a
second (recycle) shut-off valve 153, 253. The second (recycle)
shut-off valve 153 may be any suitable shut-off valve. Suitable
second (recycle) shut-off valves 153 include, but are not limited
to, ball valves and butterfly valves. For example, a suitable
second (recycle) shut-off valve 153 is available from GF Piping
Systems. In an embodiment, the second (recycle) shut-off valve 153
may be a GF Piping Systems PVC Wafer Style Butterfly Valve from GF
Piping Systems. In an embodiment, the second (recycle) shut-off
valve 153 may be automatic or manual. In an embodiment, the second
(recycle) shut-off valve 153 may be normally CLOSED.
[0190] In an embodiment, the second (recycle) shut-off valve 153
has 4-inch connections.
[0191] The second (recycle) shut-off valve 153 may be made of any
suitable corrosion-resistant material. The second (recycle)
shut-off valve 153 may be made of any suitable corrosion-resistant
metals or plastics. Suitable metals include, but are not limited
to, plastic-coated carbon steel, stainless steel, Hastelloy.RTM.
alloy, Monel.RTM. alloy and combinations thereof; and suitable
plastics include, but are not limited to, ethylene propylene diene
monomer (EPDM) rubber, polyvinylchloride (PVC) and combinations
thereof. In an embodiment, the second (recycle) shut-off valve 153
(wetted components) may be made of polyvinyl chloride (PVC) and
ethylene propylene diene monomer (EPDM) rubber.
[0192] In an embodiment, the system 100, 200 may further comprise a
second (recycle) pump 156, 256. The second (recycle) pump 156 may
be any suitable pump. Suitable second (recycle) pumps 156 include,
but are not limited to, centrifugal pumps. For example, a suitable
second (recycle) pump 156 is available from Ampco Pumps Company. In
an embodiment, the second (recycle) pump 156 may be an Ampco
Z-Series Centrifugal Pump from Ampco Pumps Company. In an
embodiment, the second (recycle) pump 156 may be a 15 HP
centrifugal pump.
[0193] In an embodiment, the second (recycle) pump 156 may have a
4-inch inlet (suction) connection and a 3-inch outlet (discharge)
connection.
[0194] The second (recycle) pump 156 may be made of any suitable
corrosion-resistant material. The second (recycle) pump 156 may be
made of any suitable corrosion-resistant metals or plastics.
Suitable metals include but are not limited to, stainless steel,
super-duplex stainless steel, AL-6XN alloy, Ni-Al-Brz alloy,
Hastelloy.RTM. alloy, Monel.RTM. alloy and combinations thereof;
and suitable plastics include, but are not limited to, chlorinated
polyvinyl chloride (CPVC) polymers, fiberglass reinforced plastic
(FRP), Kynar.RTM. polyvinylidene fluoride (PVDF) polymers,
polyethylene polymers, polypropylene polymers, polyvinyl chloride
(PVC) polymers, Teflon.RTM. perfluoroalkoxy (PFA) polymers,
Teflon.RTM. polytetrafluroethylene (PTFE) polymers, and
combinations thereof. For example, the second (recycle) pump 156,
including internal wetted components, may be made of stainless
steel, super-duplex stainless steel, AL-6XN alloy, Ni-Al-Brz alloy,
Hastelloy.RTM. alloy, Monel.RTM. alloy or FRD. In an embodiment,
the second (recycle) pump 156 (wetted components) may be made of
Ni-Al-Brz alloy.
[0195] An outlet of the second (recycle) pump 156 may be connected
to an inlet of a second manifold 162 via pipe 158.
[0196] In an embodiment, the system 100, 200 may further comprise a
second (recycle) valve 166, 266. The second (recycle) valve 166 may
be any suitable switching valve. Suitable second (recycle) valves
166 include, but are not limited to, ball and butterfly valves. For
example, a suitable second (recycle) valve 166 is available from GF
Piping Systems. In an embodiment, the second (recycle) valve 166
may be a GF Piping Systems Type 563 Electric Actuated Butterfly
Valve from GF Piping Systems. In an embodiment, the second
(recycle) valve 166 may be automatic or manual. In an embodiment,
the second (recycle) valve 166 may be electric or pneumatic
actuation. In an embodiment, the second (recycle) valve 166 may be
normally CLOSED.
[0197] In an embodiment, the second (recycle) valve 166 has 4-inch
connections.
[0198] In an embodiment, the system 100, 200 may further comprise a
third limit switch 167, 267 and a fourth limit switch 168, 268. In
an embodiment, the third limit switch 167 confirms that the second
(recycle) valve 166 is CLOSED; and the fourth limit switch 168
confirms that the second (recycle) valve 166 is OPEN.
[0199] A first outlet to the second manifold 162 may be connected
to a second inlet to the first manifold 128.
[0200] The pipe 128, 158, 162 may be made of any suitable
corrosion-resistant pipe. The pipe 128, 158, 162 may be any
suitable corrosion-resistant metals or plastics. Suitable metals
include but are not limited to, plastic-coated carbon steel,
stainless steel, super-duplex stainless steel, AL-6XN alloy,
Ni-Al-Brz alloy, Hastelloy.RTM. alloy, Monel.RTM. alloy and
combinations thereof and suitable plastics include, but are not
limited to, chlorinated polyvinyl chloride (CPVC) polymers,
fiberglass reinforced plastic (FRP), Kynar.RTM. polyvinylidene
fluoride (PVDF) polymers, polyethylene polymers, polypropylene
polymers, polyvinyl chloride (PVC) polymers, Teflon.RTM.
perfluoroalkoxy (PFA) polymers, Teflon.RTM. polytetrafluroethylene
(PTFE) polymers, and combinations thereof. In an embodiment, the
pipe 128, 158, 162 may be made of plastic-coated carbon steel. In
an embodiment, the pipe 128, 158, 162 may be made of Plasite 7159
HAR-coated carbon steel. In an embodiment, the pipe 128, 158, 162
may be made of 316 stainless steel.
[0201] In an embodiment, the pipe 128, 158, 162 may be 4-inch
pipe.
Discharge System
[0202] In an embodiment, the system 100, 200 may further comprise a
check valve 164, 264, a third discharge valve 169, 269 and a third
(discharge) shut-off valve 174, 274. A second outlet of the second
manifold 162 may be connected to an inlet of a check valve 164 or
an inlet of a third (discharge) valve 169.
[0203] In an embodiment, the system 100, 200 may further comprise a
check valve 164, 264. The check valve 164 may be any suitable check
valve. Suitable check valves 164 include, but are not limited to,
one-way valves. A second outlet of the second manifold 162 may be
connected to an inlet of a check valve 164; and an outlet of the
check valve 164 may be connected to an inlet of a third (discharge)
valve 169.
[0204] In an embodiment, the system 100, 200 may further comprise a
third (discharge) valve 169, 269. The third (discharge) valve 169
may be any suitable switching valve. Suitable discharge valves
include, but are not limited to, ball valves. For example, a
suitable third (discharge) valve 169 is available from GF Piping
Systems. In an embodiment, the third (discharge) valve 169 may be a
GF Piping Systems Type 546 Electric Actuated Ball Valve from GF
Piping Systems. In an embodiment, the third (discharge) valve 169
may be automatic or manual. In an embodiment, the third (discharge)
valve 169 may be electric or pneumatic actuation. In an embodiment,
the third (discharge) valve 169 may be normally CLOSED.
[0205] In an embodiment, the third (discharge) valve 169 may have
2-inch connections.
[0206] In an embodiment, the system 100, 200 may further comprise a
fifth limit switch 170, 270 and a sixth limit switch 171, 271. In
an embodiment, the fifth limit switch 170, 270 confirms that the
third (discharge) valve 169 is OPEN; and the sixth limit switch
171, 271 confirms that the third (discharge) valve 169 is
CLOSED.
[0207] A second outlet of the second manifold 162 may be connected
to an inlet of a third (discharge) valve 169; and an outlet of the
third (discharge) valve 169 may be connected to an inlet of a
second (discharge) shut-off valve 174 via pipe 172.
[0208] In an embodiment, the system 100, 200 may further comprise a
third (discharge) shut-off valve 174, 274. The third (discharge)
shut-off valve 174 may be any suitable shut-off valve. Suitable
third (discharge) shut-off valves 174 include, but are not limited
to, ball valves and butterfly valves. For example, a suitable third
(discharge) shut-off valve 174 is available from GF Piping Systems.
In an embodiment, the third (discharge) shut-off valve 174 may be a
GF Piping Systems Type 546 PVC Ball Valve from GF Piping Systems.
In an embodiment, the third (discharge) shut-off valve 174 may be
automatic or manual. In an embodiment, the third (discharge)
shut-off valve 174 may be normally CLOSED.
[0209] In an embodiment, the third (discharge) shut-off valve 174
may have 2-inch connections.
[0210] The third (discharge) shut-off valve 174 may be made of any
suitable corrosion-resistant material. The third (discharge)
shut-off valve 174 may be made of any suitable corrosion-resistant
metals or plastics. Suitable metals include, but are not limited
to, plastic-coated carbon steel, stainless steel, Hastelloy.RTM.
alloy, Monel.RTM. alloy and combinations thereof; and suitable
plastic include, but are not limited to, ethylene propylene diene
monomer (EPDM) rubber, polyvinylchloride (PVC) and combinations
thereof. In an embodiment, the third (discharge) shut-off valve 174
(wetted components) may be made of polyvinyl chloride (PVC) and
ethylene propylene diene monomer (EPDM) rubber.
[0211] An outlet of the third (discharge) valve 169 may be
connected to an inlet of the third (discharge) shut-off valve 174
via pipe 172. An outlet of the third (discharge) shut-off valve 174
may be connected to a discharge outlet 176 via pipe 175.
[0212] The pipe 172, 175 may be made of any suitable
corrosion-resistant pipe. The pipe 172, 175 may be made of any
suitable corrosion-resistant metals or plastics. Suitable metals
include, but are not limited to, plastic-coated carbon steel,
stainless steel, super-duplex stainless steel, AL-6XN alloy,
Ni-Al-Brz alloy, Hastelloy.RTM. alloy, Monel.RTM. alloy and
combinations thereof and suitable plastics include, but are not
limited to, chlorinated polyvinyl chloride (CPVC) polymers,
fiberglass reinforced plastic (FRP), Kynar.RTM. polyvinylidene
fluoride (PVDF) polymers, polyethylene polymers, polypropylene
polymers, polyvinyl chloride (PVC) polymers, Teflon.RTM.
perfluoroalkoxy (PFA) polymers, Teflon.RTM. polytetrafluroethylene
(PTFE) polymers, and combinations thereof. In an embodiment, the
pipe 172, 175 may be made of plastic-coated carbon steel. In an
embodiment, the pipe 172, 175 may be made of Plasite 7159
HAR-coated carbon steel. In an embodiment, the pipe 172, 175 may be
made of 316 stainless steel.
[0213] In an embodiment, the pipe 172, 175 may be 2-inch pipe.
Optional Sensors and Meters
[0214] In an embodiment, the system 100, 200 may further comprise a
first flow meter 122, 222, a first temperature sensor 130, 230, a
first conductivity meter 131, 231, an optional second conductivity
meter 132, 232 (not shown), and/or a second flow meter 173,
273.
[0215] The first flow meter 122 may be fluidly connected to pipe
120.
[0216] The first flow meter 122 may be any suitable flow meter.
Suitable first flow meters 122 include, but are not limited to,
magnetic, paddlewheel, ultrasonic vortex and insertion-type vortex
flow meters. For example, a suitable first flow meter 122 is
available from Georg Fischer Signet LLC. In an embodiment, the
first flow meter 122 may be a Signet 2536 Rotor-X Paddlewheel Flow
Sensor from Georg Fischer Signet LLC. In an embodiment, the first
flow sensor 122 may be electrically connected to the PLC or
computing device 600.
[0217] The first temperature sensor 130 may be fluidly connected to
the first manifold 128.
[0218] The first temperature sensor 130 may be any suitable
temperature measuring device. For example, a suitable first
temperature sensor 130 is available from Ashcroft Inc. In an
embodiment, the first temperature sensor 130 may be a Bi-Metallic
Dial Thermometer from Ashcroft Inc. In an embodiment, the first
temperature sensor 130 may be electrical or manual.
[0219] The first conductivity meter 131 may be fluidly connected to
the first manifold 128; and the optional second conductivity meter
132 (not shown) may be fluidly connected to the first manifold
128.
[0220] The first conductivity meter 131 monitors the conductivity
of the inlet (feed) or condensed (recycled) wastewater from the
external wastewater source. If the first conductivity meter 131
measures a predetermined minimum conductivity (e.g., indicating
presence of oil in feed water), the system 100 is shut off.
[0221] The first conductivity meter 131 may be any suitable
conductivity meter. For example, a suitable first conductivity
meter 131 is available from Cole-Parmer Instrument Company. In an
embodiment, the first conductivity meter 131 may be a Model
ML-19504-04 Toroidal Conductivity Sensor from Cole-Parmer
Instrument Company. In an embodiment, the first conductivity sensor
131 may be electrically connected to the PLC or computing device
600. In an embodiment, the first conductivity sensor 131 may have a
range from about 0 .mu.S/cm to about 1,000,000 .mu.S/cm (and any
range or value there between).
[0222] The optional second conductivity meter 132 (not shown)
monitors the conductivity of the inlet (feed) or condensed
(recycle) wastewater from the external wastewater source. If the
second conductivity meter 132 indicates the condensed wastewater
(brine) has reached a predetermined maximum conductivity, the third
(discharge) valve 169 is switched to the OPEN position, the third
(discharge) shut-off valve 174 is switched to the OPEN position,
and the second (recycle) valve 166 is switched to the CLOSED
position.
[0223] The optional second conductivity meter 132 may be any
suitable conductivity meter. For example, a suitable first
conductivity meter 132 is available from Cole-Parmer Instrument
Company. In an embodiment, the first conductivity meter 132 may be
a Model ML-19504-04 Toroidal Conductivity Sensor electrically
connected to a Model ML-94785-12 Process Meter from Cole-Parmer
Instrument Company. In an embodiment, the second conductivity
sensor 132 may be electrically connected to the PLC or computing
device 600. In an embodiment, the second conductivity sensor 132
may have a range from about 0 .mu.S/cm to about 1,000,000 .mu.S/cm
(and any range or value there between).
[0224] The second flow meter 173 may be fluidly connected to pipe
172. The second flow meter 173 monitors the flow rate of the
discharge to the discharge outlet 176.
[0225] The second flow meter 173 may be any suitable flow meter.
Suitable second flow meters 173 include, but are not limited to,
magnetic, paddlewheel, ultrasonic vortex and insertion-type vortex
flow meters. For example, a suitable second flow meter 173 is
available from Georg Fischer Signet LLC. In an embodiment, the
second flow meter 173 may be a Signet 2536 Rotor-X Paddlewheel Flow
Sensor from Georg Fischer Signet LLC. In an embodiment, the second
flow meter 173 may be electrically connected to the PLC or
computing device 600.
Optional Limit/Level, Pressure and Temperature Switches
[0226] In an embodiment, the system 100, 200 may further comprise a
first pressure switch 110, 210, an air temperature sensor 140, 240,
a first high differential pressure switch 147, 247, a second high,
high differential pressure switch 148, 248, a first high, high
limit switch 149, 249, a low limit switch 150,250, a high limit
switch 151, 251, a second high, high limit switch 152, 252, and a
second pressure switch 159, 259.
[0227] The first pressure switch 110 monitors pressure of inlet
wastewater to the first (feed) pump 118. The first pressure switch
110 may be any suitable pressure switch. For example, a suitable
first pressure switch 110 is available from AutomationDirect.com
Inc. In an embodiment, the first pressure switch 110 may be a
ProSense.RTM. MPS25 Series Mechanical Pressure Switch from
AutomationDirect.com Inc.
[0228] The first pressure switch 110 may be fluidly connected to
the pipe 108.
[0229] The first high differential pressure switch 147 monitors the
air pressure in the container 139, 339. If the first high
differential pressure switch 147 is activated, the air blower 142
is operating. In an embodiment, the first high differential
pressure switch 147 may be set to +/-0.15 inches water column.
[0230] The first high differential pressure switch 147 may be any
suitable differential pressure sensor. For example, a suitable
first high differential pressure switch 147 is available from Dwyer
Instruments Inc. In an embodiment, the first high differential
pressure switch 147 may be a Series 3000 Photohelic Differential
Pressure Gage from Dwyer Instruments Inc. In an embodiment, the
first high differential pressure switch 147 has a range from about
0 to about 0.5 inches water column.
[0231] The first high differential pressure switch 147 may be
fluidly connected to the container 139, 339.
[0232] The second high, high differential pressure switch 148 also
monitors air pressure in the container. If the second high, high
differential pressure switch 148 is activated, the mist arresting
system 144 may be blocked due to flooding or scale build-up. In an
embodiment, the second high, high differential pressure switch 148
may be set to about +/-0.40 inches water column.
[0233] The second high, high differential pressure switch 148 may
be any suitable differential pressure sensor. For example, a
suitable second high, high differential pressure switch 148 is
available from Dwyer Instruments Inc. In an embodiment, the second
high, high differential pressure sensor 148 may be a Series 3000MR
Photohelic Differential Pressure Gage from Dwyer Instruments Inc.
In an embodiment, the second high, high differential pressure
switch 148 may have a range from about 0 to about 0.5 inches water
column.
[0234] The second high, high differential pressure switch 148 may
be fluidly connected to the container 139, 339.
[0235] The first high, high limit switch 149, low limit switch 150
and high limit switch 151 monitor various water levels in the sump
(bottom) of the container 139, 339. The second high, high limit
switch 152 monitors water levels in a secondary containment.
[0236] The high, high limit switches 149, 152, low limit switch
150, and high limit switch 151 may be any suitable water level
switches. Suitable water level switches include, but are not
limited to, capacitive proximity, float, magnetic and vibrating
fork. For example, the high, high limit switches 149, 152, low
limit switch 150, and high limit switch 151 are available from
AutomationDirect.com Inc. In an embodiment, the high, high limit
switches 149, 152, low limit switch 150, and high limit switch 151
may be TU Series Model M18 Round Inductive Proximity Sensors from
AutomationDirect.com Inc.
[0237] The first high, high limit switch 149, low limit switch 150,
and high limit switch 151 may be fluidly connected near the sump
(bottom) of the container 139, 339.
[0238] The second high, high limit switch 152 may be fluidly
connected outside the container 139, 339 for monitoring water
levels in the secondary containment.
[0239] The second pressure switch 159 monitors pressure of
condensed (recycle) wastewater from the second (recycle) pump 156.
The second pressure switch 159 may be any suitable pressure switch.
For example, a suitable second pressure switch 159 is available
from AutomationDirect.com Inc. In an embodiment, the first pressure
switch 159 may be a ProSense.RTM. MPS25 Series Mechanical Pressure
Switch from AutomationDirect.com Inc.
[0240] The second pressure switch 159 may be fluidly connected to
pipe 158.
[0241] In an embodiment, a pressure gauge 160 displays the pressure
of the condensed (recycle) wastewater from the second (recycle)
pump 156. The pressure gauge 160 may be fluidly connected to pipe
158.
Optional Acid Conditioning System
[0242] In an embodiment, the system 100 may further comprise an
optional acid conditioning system 177. The acid conditioning system
177 comprises an acid tote 178 and an acid metering pump 180.
[0243] The acid may be any suitable acid. Suitable acids include,
but are not limited to, hydrochloric acid and sulfuric acid. In an
embodiment, the acid may be hydrochloric acid (20 baume). In an
embodiment, the acid may be sulfuric acid (98%). In an embodiment,
the desired pH of the wastewater is about 6.5 or below to minimize
calcium carbonate scaling. In an embodiment, the desired pH of the
wastewater may be above 6.5 if a scale inhibitor is added to
minimize carbonate and non-carbonate scaling. In an embodiment, the
amount of acid solution added varies, depending on inlet water
conditions (e.g., pH, alkalinity).
[0244] In an embodiment, the desired pH of the wastewater may be
above 6.5 if a scale inhibitor is added to minimize carbonate and
non-carbonate scaling.
[0245] An outlet of the acid tote 178 may be fluidly connected to
an inlet of the acid metering pump 180 via tubing 179; and an
outlet of the acid metering pump 180 is fluidly connected to the
container 139, 339 or to the pipe 154 (shown) via tubing 181.
[0246] The acid tote 178 may be any suitable acid tote or other
bulk chemical storage unit. Suitable acid totes include, but are
not limited to, an industry standard shipping tote. For example, a
suitable acid tote 178 is available from National Tank Outlet. In
an embodiment, the acid tote 178 may be a 275 gallon or a 330
gallon industry standard shipping tote. In an embodiment, the acid
tote 178 may be a 55 gallon drum.
[0247] The acid metering pump 180 may be any suitable acid metering
pump. Suitable acid metering pumps include, but are not limited to,
electronic diaphragm, peristaltic and positive displacement pumps.
For example, a suitable acid metering pump 180 is available from
Anko Products, Inc. In an embodiment, the acid metering pump 180
may be a self-priming peristaltic pump from Anko Products, Inc. In
an embodiment, the acid metering pump 180 may be a Mityflex Model
907 self-priming peristaltic pump from Anko Products, Inc.
[0248] The tubing 179, 181 may be made of any suitable
corrosion-resistant tubing. The tubing 179, 181 may be made of any
suitable corrosion-resistant metals or plastics. Suitable metals
include but are not limited to, AL-6XN alloy, Hastelloy.RTM. alloy,
Monel.RTM. alloy, and combinations thereof; and suitable plastics
include, but are not limited to, chlorinated polyvinyl chloride
(CPVC) polymers, fiberglass reinforced plastic (FRP), Kynar.RTM.
polyvinylidene fluoride (PVDF) polymers, polyethylene polymers,
polypropylene polymers, polyvinyl chloride (PVC) polymers,
Teflon.RTM. perfluoroalkoxy (PFA) polymers, Teflon.RTM.
polytetrafluroethylene (PTFE) polymers, and combinations thereof.
For example, suitable tubing 179, 181 may be made of Teflon.RTM.
PFA or PTFE.
[0249] In an embodiment, the acid conditioning system 177 may
further comprise an acid flow meter (not shown). The acid flow
meter may be fluidly connected to tubing 181. The acid flow meter
measures the flow rate of the acid solution.
[0250] The acid flow meter may be any suitable flow meter. Suitable
acid flow meters include, but are not limited to, paddlewheel,
ultrasonic vortex and insertion-type vortex flow meters. For
example, a suitable acid flow meter is available from ProMinent. In
an embodiment, the acid flow meter may be a Model DulcoFlow DFMa
from ProMinent with built-in signal transmission capability.
Optional Bactericide Conditioning System
[0251] In an embodiment, the system 100 may further comprise an
optional bactericide conditioning system 182. The bactericide
conditioning system 182 comprises a bactericide tote 183 and a
bactericide metering pump 185.
[0252] The bactericide may be any suitable bactericide. Suitable
bactericide includes, but is not limited to, bleach, bromine,
chlorine dioxide (generated), 2,2-dibromo-3-nitrilo-propionade
(DBNPA), glutaraldehyde, isothiazolin (1.5%) and ozone (generated).
In an embodiment, the bactericide may be selected from the group
consisting of bleach (12.5%), bromine, chlorine dioxide
(generated), DBNPA (20%), glutaraldehyde (50%), isothiazolin (1.5%)
and ozone (generated). In an embodiment, the desired bactericide
concentration is from about 10 ppm to about 1000 ppm (and any range
or value there between). The amount of bactericide solution added
to the wastewater varies, depending on inlet water condition.
[0253] An outlet of the bactericide tote 183 may be fluidly
connected to an inlet of the bactericide metering pump 185 via
tubing 184; and an outlet of the bactericide metering pump 185 may
be fluidly connected to the container 139, 339 or to the pipe 154
(shown) via tubing 186.
[0254] The bactericide tote 183 may be any suitable bactericide
tote or other bulk chemical storage unit. Suitable bactericide
totes include, but are not limited to, an industry standard
shipping tote. For example, a suitable bactericide tote 183 is
available from National Tank Outlet. In an embodiment, the
bactericide tote 183 may be a 275 gallon or 330 gallon industry
standard shipping tote. In an embodiment, the bactericide tote 183
may be a 55 gallon drum or a 5 gallon pail.
[0255] In an alternative embodiment, the bactericide tote 183 may
be replaced with a suitable bactericide generating apparatus (not
shown). For example, a suitable bactericide apparatus is available
from Miox Corporation. In an embodiment, the bactericide generating
apparatus (not shown) may be a Model AE-8 from Miox
Corporation.
[0256] The bactericide metering pump 185 may be any suitable
bactericide metering pump. Suitable bactericide metering pumps
include, but are not limited to, electronic diaphragm, peristaltic
and positive displacement pumps. For example, a suitable
bactericide metering pump 185 is available from Anko Products, Inc.
In an embodiment, the bactericide metering pump 185 may be a
self-priming peristaltic pump from Anko Products, Inc. In an
embodiment, the bactericide metering pump 185 may be a Mityflex
Model 907 self-priming peristaltic pump from Anko Products,
Inc.
[0257] The tubing 184, 186 may be made of any suitable
corrosion-resistant tubing. The tubing 184, 186 may be made of any
suitable corrosion-resistant metals or plastics. Suitable metals
include, but are not limited to, AL-6XN alloy, Hastelloy.RTM.
alloy, Monel.RTM. alloy and combinations thereof; and suitable
plastics include, but are not limited to, chlorinated polyvinyl
chloride (CPVC) polymers, fiberglass reinforced plastic (FRP),
Kynar.RTM. polyvinylidene fluoride (PVDF) polymers, polyethylene
polymers, polypropylene polymers, polyvinyl chloride (PVC)
polymers, Teflon.RTM. perfluoroalkoxy (PFA) polymers, Teflon.RTM.
polytetrafluroethylene (PTFE) polymers, and combinations thereof.
In an embodiment, the tubing 184, 186 may be made of Teflon.RTM.
PFA or PTFE.
[0258] In an embodiment, the bactericide conditioning system 182
may further comprise an optional bactericide flow meter (not
shown). The bactericide flow meter may be fluidly connected to
tubing 186. The bactericide flow meter measures the flow rate of
the bactericide solution.
[0259] The bactericide flow meter may be any suitable flow meter.
Suitable bactericide flow meters include, but are not limited to,
paddlewheel, ultrasonic vortex and insertion-type vortex flow
meters. For example, a suitable bactericide flow meter is available
from ProMinent. In an embodiment, the bactericide flow meter may be
a Model DulcoFlow DFMa from ProMinent with built-in signal
transmission capability.
Optional Scale Inhibition Conditioning System
[0260] In an embodiment, the system 100 may further comprise an
optional scale inhibition conditioning system 187. The scale
inhibition conditioning system 187 comprises a scale inhibition
tote 188 and a scale inhibition metering pump 190.
[0261] The scale inhibitor may be any suitable scale inhibitor or
blend of scale inhibitors. A suitable scale inhibitor includes, but
is not limited to, inorganic phosphates, organophosphorous
compounds and organic polymers. In an embodiment, the scale
inhibitor may be selected from the group consisting of organic
phosphate esters, polyacrylates, phosphonates, polyacrylamides,
polycarboxylic acids, polymalates, polyphosphincocarboxylates,
polyphosphates and polyvinylsylphonates. In an embodiment, the
desired scale inhibitor concentration is from about 10 ppm to about
100 ppm (and any range or value there between). In an embodiment,
the desired scale inhibitor concentration is from about 2 ppm to
about 20 ppm (and any range or value there between). The amount of
scale inhibitor solution added to the wastewater varies, depending
on inlet water condition.
[0262] An outlet of the scale inhibition tote 188 may be fluidly
connected to an inlet of the scale inhibition metering pump 190 via
tubing 189; and an outlet of the scale inhibition metering pump 190
may be fluidly connected to container 139, 339 (shown) or to pipe
154 via tubing 191.
[0263] The scale inhibition tote 188 may be any suitable scale
inhibition tote or other bulk chemical storage unit. Suitable scale
inhibition totes include, but are not limited to, an industry
standard shipping tote. For example, a suitable scale inhibition
tote 188 is available from National Tank Outlet. In an embodiment,
the scale inhibition tote 188 may be a 275 gallon or 330 gallon
industry standard shipping tote. In an embodiment, the scale
inhibition tote 188 may be a 55 gallon drum or a 5 gallon pail.
[0264] The scale inhibition metering pump 190 may be any suitable
scale inhibitor metering pump. Suitable scale inhibition metering
pumps include, but are not limited to, electronic diaphragm,
peristaltic and positive displacement pumps. For example, a
suitable scale inhibition metering pump 190 is available from Anko
Products, Inc. In an embodiment, the scale inhibition metering pump
190 may be a self-priming peristaltic pump from Anko Products, Inc.
In an embodiment, the scale inhibition metering pump 190 may be a
Mityflex Model 907 self-priming peristaltic pump from Anko
Products, Inc.
[0265] The tubing 189, 191 may be made of any suitable
corrosion-resistant tubing. The tubing 189, 191 may be made of any
suitable corrosion-resistant metals or plastics. Suitable metals
include but are not limited to, plastic-coated carbon steel,
stainless steel, super-duplex stainless steel, AL-6XN alloy,
Hastelloy.RTM. alloy, Monel.RTM. alloy and combinations thereof and
suitable plastics include, but are not limited to, chlorinated
polyvinyl chloride (CPVC) polymers, fiberglass reinforced plastic
(FRP), Kynar.RTM. polyvinylidene fluoride (PVDF) polymers,
polyethylene polymers, polypropylene polymers, polyvinyl chloride
(PVC) polymers, Teflon.RTM. perfluoroalkoxy (PFA) polymers,
Teflon.RTM. polytetrafluroethylene (PTFE) polymers, and
combinations thereof. In an embodiment, the tubing 189, 191 may be
made of Teflon.RTM. PFA or PTFE.
[0266] In an embodiment, the scale inhibition conditioning system
187 may further comprise an optional scale inhibition flow meter
(not shown). The scale inhibition flow meter may be fluidly
connected to tubing 191. The scale inhibition flow meter measures
the flow rate of the scale inhibitor solution.
[0267] The scale inhibitor flow meter may be any suitable flow
meter. Suitable scale inhibitor flow meters include, but are not
limited to, paddlewheel, ultrasonic vortex and insertion-type
vortex flow meters. For example, a suitable scale inhibitor flow
meter is available from ProMinent. In an embodiment, the scale
inhibitor flow meter may be a Model DulcoFlow DFMa from ProMinent
with built-in signal transmission capability.
Optional Defoamer System
[0268] In an embodiment, the system 100 may further comprise an
optional defoamer system 192. The defoamer system 192 comprises a
defoamer tote 193 and a defoamer pump 195.
[0269] The defoamer may be any suitable defoamer. Suitable defoamer
includes, but is not limited to, alcohols, glycols, insoluable
oils, silicone polymers and stearates. In an embodiment, the
defoamer may be selected from the group consisting of fatty
alcohols, fatty acid esters, fluorosilicones, polyethylene glycol,
polypropylene glycol, silicone glycols and polydimethylsiloxane. In
an embodiment, the desired defoamer concentration is from about 10
ppm to about 100 ppm (and any range or value there between). In an
embodiment, the desired defoamer concentration is from about 2 ppm
to about 20 ppm (and any range or value there between). The amount
of defoamer solution added to the wastewater varies, depending on
inlet water condition.
[0270] An outlet of the defoamer tote 193 may be fluidly connected
to an inlet of the defoamer metering pump 195 via tubing 194; and
an outlet of the defoamer metering pump 195 may be fluidly
connected to container 139, 339 (shown) or to pipe 154 via tubing
196.
[0271] The defoamer tote 193 may be any suitable defoamer tote or
other bulk chemical storage unit. Suitable defoamer totes include,
but are not limited to, an industry standard shipping tote. For
example, a suitable defoamer tote 193 is available from National
Tank
[0272] Outlet. In an embodiment, the scale defoamer tote 193 may be
a 275 gallon or 330 gallon industry standard shipping tote. In an
embodiment, the defoamer tote 193 may be a 55 gallon drum or a 5
gallon pail.
[0273] The defoamer metering pump 195 may be any suitable defoamer
metering pump. Suitable defoamer metering pumps include, but are
not limited to, electronic diaphragm, peristaltic, and positive
displacement pumps. For example, a suitable defoamer metering pump
195 is available from Anko Products, Inc. In an embodiment, the
defoamer metering pump 195 may be a self-priming peristaltic pump
from Anko Products, Inc. In an embodiment, the defoamer metering
pump 195 may be a Mityflex Model 907 self-priming peristaltic pump
from Anko Products, Inc.
[0274] The tubing 194, 196 may be made of any suitable
corrosion-resistant tubing. The tubing 194, 196 may be made of any
suitable corrosion-resistant metals or plastics. Suitable metals
include, but are not limited to, plastic-coated carbon steel,
stainless steel, super-duplex stainless steel, AL-6XN alloy,
Hastelloy.RTM. alloy, Monel.RTM. alloy and combinations thereof and
suitable plastics include, but are not limited to, chlorinated
polyvinyl chloride (CPVC) polymers, fiberglass reinforced plastic
(FRP), Kynar.RTM. polyvinylidene fluoride (PVDF) polymers,
polyethylene polymers, polypropylene polymers, polyvinyl chloride
(PVC) polymers, Teflon.RTM. perfluoroalkoxy (PFA) polymers,
Teflon.RTM. polytetrafluroethylene (PTFE) polymers, and
combinations thereof. In an embodiment, the tubing 194, 196 may be
made of Teflon.RTM. PFA or PTFE.
[0275] In an embodiment, the defoamer conditioning system 192 may
further comprise an optional defoamer flow meter (not shown). The
defoamer flow meter may be fluidly connected to tubing 196. The
defomer flow meter measures the flow rate of the defoamer
solution.
[0276] The defoamer flow meter may be any suitable flow meter.
Suitable defoamer flow meters include, but are not limited to,
paddlewheel, ultrasonic vortex and insertion-type vortex flow
meters. For example, a suitable defoamer flow meter is available
from ProMinent. In an embodiment, the defoamer flow meter may be a
Model DulcoFlow DFMa from ProMinent with built-in signal
transmission capability.
System for Spray Evaporation of Water Illustrating Alternative
Embodiments
First Alternative Embodiment
[0277] A schematic of an exemplary system 400, 500 for spray
evaporation of water according to another embodiment of the present
invention is shown in FIGS. 4A-5D. The system 400, 500 comprises a
wastewater inlet 404, 504, a pump 420, 520, an air blower 436, 536,
a manifold 439, 539, a spray nozzle 442, 542, a container 444, 544,
a demister element 448, 548, and a discharge outlet 458, 558.
[0278] In an embodiment, the system 400, 500 is capable of
evaporating between about 2,000 to about 10,000 gallons of
wastewater per day (see FIGS. 4A-5D). If a higher throughput is
desired, a plurality of system 400, 500 may be used in parallel to
treat the wastewater.
Inlet System
[0279] The wastewater inlet 404, 504 may be connected to an inlet
of the first 3-way valve 416 via a pipe 408, 508. An outlet of the
3-way valve 416 may be connected to an inlet of the pump 420, 520
via a pipe 418, 518.
[0280] The wastewater inlet 404, 504 may be any suitable wastewater
inlet that can handle up to about 40 psi. Suitable wastewater
inlets include, but are not limited to, flange connections,
cam-lock fittings and hammer unions. In an embodiment, the
wastewater inlet 404, 504 is a flange connection (see FIGS. 5A-5D).
The wastewater inlet 404, 504 permits connection to an external
wastewater source via a wastewater suction header 402. The water
inlet 404, 504 may be connected to the external wastewater source
via a hose, pipe or other means customary in the art.
[0281] In an embodiment, the system 400, 500 may further comprise a
first 3-way valve 416, 516. The first 3-way valve 416 may be any
suitable 3-way valve. The first 3-way valve 416 may be automatic or
manual. The first 3-way valve 416 may be electric or pneumatic
actuation. Suitable 3-way valves include, but are not limited to,
ball valves. For example, a suitable first 3-way valve 416 is
available from GF Piping Systems. In an embodiment, the first 3-way
valve 416 may be a Georg Fischer Type 543 3-Way Ball Valve from GF
Piping Systems.
[0282] The pump 420, 520 may be any suitable pump. Suitable pumps
include, but are not limited to, positive suction pumps. For
example, a suitable pump 420, 520 is available from Ampco. In an
embodiment, the pump 420, 520 may be a 3 to 5 horse power positive
suction pump from MP Pumps.
[0283] The pump 420, 520 may be made of any suitable
corrosion-resistant material. The pump 420, 520 may be made of any
suitable corrosion-resistant metals or plastics. Suitable metals
include, but are not limited to, cast iron, stainless steel,
super-duplex stainless steel, AL-6XN alloy, Ni-Al-Brz alloy,
Hastelloy.RTM. alloy, Monel.RTM. alloy and combinations thereof and
suitable plastics include, but are not limited to, chlorinated
polyvinyl chloride (CPVC) polymers, fiberglass reinforced plastic
(FRP), Kynar.RTM. polyvinylidene fluoride (PVDF) polymers,
polyethylene polymers, polypropylene polymers, polyvinyl chloride
(PVC) polymers, Teflon.RTM. perfluoroalkoxy (PFA) polymers,
Teflon.RTM. polytetrafluroethylene (PTFE) polymers, and
combinations thereof.
[0284] For example, the pump 420, 520, including internal wetted
components, may be made of stainless steel, super-duplex stainless
steel, AL-6XN alloy, Ni-Al-Brz alloy, Hastelloy.RTM. alloy,
Monel.RTM. alloy or FRD. In an embodiment, the pump 420, 520,
including internal wetted components, may be made of super-duplex
stainless steel. In an embodiment, pump 420, 520 may be made of
cast iron if a shorter service life is acceptable.
[0285] The pipe 418, 518 may be made of any suitable
corrosion-resistant pipe. The pipe 418, 518 may be any suitable
metal or plastic pipe. Suitable metals include but are not limited
to, plastic-coated carbon steel, stainless steel, super-duplex
stainless steel, AL-6XN alloy, Ni-Al-Brz alloy, Hastelloy.RTM.
alloy, Monel.RTM. alloy and combinations thereof; and suitable
plastics include, but are not limited to, chlorinated polyvinyl
chloride (CPVC) polymers, fiberglass reinforced plastic (FRP),
Kynar.RTM. polyvinylidene fluoride (PVDF) polymers, polyethylene
polymers, polypropylene polymers, polyvinyl chloride (PVC)
polymers, Teflon.RTM. perfluoroalkoxy (PFA) polymers, Teflon.RTM.
polytetrafluroethylene (PTFE) polymers, and combinations thereof.
In an embodiment, the pipe 418, 518 may be made of plastic-coated
carbon steel. In an embodiment, the pipe 418, 518 may be made of
Plasite 7159 HAR-coated carbon steel. In an embodiment, the pipe
418, 518 may be made of 316 stainless steel.
[0286] In an embodiment, the pipe 418, 518 may be 2-inch pipe.
[0287] An outlet of the pump 420, 520 may be connected to an inlet
of the second 3-way valve 432, 532 via pipe(s) 422, 426, 522, 526.
A first outlet of the second 3-way valve 432, 532 may be connected
to a manifold 439, 539 via a pipe 438, 538.
[0288] A first outlet of the air blower 436' may be fluidly
connected to a blower inlet of the manifold 439, 539 opposite a
spray outlet of the manifold 439, 539, a second outlet of a second
air blower 436'' may be fluidly connected to a second blower inlet
of the manifold 439, 539 opposed to a second spray outlet of the
manifold 439, 539, and so on.
[0289] In an embodiment, each outlet of the air blower 436, 536 may
be connected to its corresponding blower inlet of the manifold 439,
539 via tubing. In an embodiment, the tubing may be made of 316
stainless steel. In an embodiment, the tubing may be 3/8-inch
tubing.
[0290] In an embodiment, each spray outlet of the pipe 438, 538 may
be connected to an inlet of the spray nozzle 442 via tubing. In an
embodiment, each spray outlet of the manifold 439, 539 comprises
about 4 to about 6 tubes (see FIGS. 5A-5B). In an embodiment, the
tubing may be made of 316 stainless steel. In an embodiment, the
tubing may be 3/8-inch tubing.
[0291] In an embodiment, the system 400 may further comprise a
second 3-way valve 432, 532. The second 3-way valve 432, 532 may be
any suitable 3-way valve. The second 3-way valve 432, 532 may be
automatic or manual. The second 3-way valve 432, 532 may be
electric or pneumatic actuation. Suitable 3-way valves include, but
are not limited to, ball valves. For example, a suitable second
3-way valve 432, 532 is available from GF Piping Systems. In an
embodiment, the second 3-way valve 432, 532 may be a Georg Fischer
Type 543 3-Way Ball Valve from GF Piping Systems. In an embodiment,
the first 3-way valve 416 and the second 3-way valve 432, 532 may
be the same type.
[0292] In an embodiment, the second 3-way valve 432, 532 may have
2-inch connections.
[0293] The air blowers 436, 536 may be any suitable air blower. The
air blower 436, 536 may be automatic or manual. The air blowers
436, 536 may be electric or hydraulic (see FIGS. 4A-4C). Suitable
air blowers include, but are not limited to, variable-speed air
blowers. For example, a suitable plurality of air blowers 436, 536
is available from Curtec. In an embodiment, the air blower 436, 536
may be a variable-speed air blower capable of moving from about 1 k
to about 35 k CFM from Curtec. In an embodiment, the air blower
436, 536 may be a variable-speed air blower capable of moving from
about 3 k to about 18 k CFM total from Curtec. In an embodiment,
the air blower 436, 536 may be a variable-speed air blower capable
of moving from about 15 k to about 35 k CFM total from Curtec.
[0294] The pipe 422, 426, 438, 522, 526, 538 may be made of any
suitable corrosion-resistant pipe. The pipe 422, 426, 438, 522,
526, 538 may be made of any suitable corrosion-resistant metals or
plastics. Suitable metals include, but are not limited to,
plastic-coated carbon steel, stainless steel, super-duplex
stainless steel, AL-6XN alloy, Ni-Al-Brz alloy, Hastelloy.RTM.
alloy, Monel.RTM. alloy and combinations thereof; and suitable
plastics include, but are not limited to, chlorinated polyvinyl
chloride (CPVC) polymers, fiberglass reinforced plastic (FRP),
Kynar.RTM. polyvinylidene fluoride (PVDF) polymers, polyethylene
polymers, polypropylene polymers, polyvinyl chloride (PVC)
polymers, Teflon.RTM. perfluoroalkoxy (PFA) polymers, Teflon.RTM.
polytetrafluroethylene (PTFE) polymers, and combinations thereof.
In an embodiment, the pipe 422, 426, 438, 522, 526, 538 may be made
of plastic-coated carbon steel. In an embodiment, the pipe 422,
426, 438, 522, 526, 538 may be made of Plasite 7159 HAR-coated
carbon steel. In an embodiment, the pipe 422, 426, 438, 522, 526,
538 may be made of 316 stainless steel.
[0295] In an embodiment, the pipe 422, 426, 438, 522, 526, 538 may
be 2-inch pipe.
[0296] An outlet of the air blower 436, 536 may be connected to an
inlet of the spray nozzle 442 via the manifold 439, 539, as
discussed above. An outlet of the spray nozzle 442 discharges water
droplets inside the container 444, 544. An upper portion or top
side of the container 444, 544 is enclosed with the demister
element 448, 548 to retain the water droplets inside the container
444, 544. The demister element 448, 548 is secured to and supported
by the container 444, 544 in a manner customary in the art. In an
embodiment, a water to air ratio may range from about 15
GPM/150,000 CFM to about 100 GPM/60,000 CFM (and any range or value
there between). In an embodiment, the water to air ratio is about
16 GPM/127,000 CFM.
[0297] At least some of the water droplets evaporate to form water
vapor. The water vapor passes through the demister element 448, 548
and out the evaporated water outlet 450. Any un-evaporated water is
retained by the demister element 448, 548 and falls to the sump
(bottom) of the container 444, 544.
[0298] The spray nozzle 442 may be any suitable spray nozzle.
Suitable spray nozzles include, but are not limited to, rotary
atomizers. For example, a suitable spray nozzle 442 is available
from Ledebuhr Industries. In an embodiment, the spray nozzle 442
may be a variable-speed rotary atomizer from Ledebuhr Industries.
In an embodiment, the rotary atomizer may be capable of high flow.
In an embodiment, the rotary atomizer has a plurality of spray
heads. In an embodiment, the rotary atomizer may be capable of
about 8 gallon per minute (GPM) flow per spray head. In an
embodiment, the rotary atomizer produces water droplet sizes from
about 50 .mu.m to about 300 .mu.m. In an embodiment, the rotary
atomizer may produce water droplet sizes from about 50 .mu.m to
about 150 .mu.m. In an embodiment, the spray heads are positioned
at the discharge point of the air blower. Alternatively, the spray
heads are positioned inside the container.
[0299] The spray nozzle 442 may be made of any suitable
corrosion-resistant material. The spray nozzle 442 may be made of
any suitable corrosion-resistant metals. Suitable metals, include,
but are not limited to, stainless steel, Hastelloy.RTM. alloy,
Monel.RTM. alloy and combinations thereof. In an embodiment, the
spray nozzle 442 (spray head) may be made of 316 stainless
steel.
[0300] The container 444, 544 may be any suitable container. The
container 444, 544 may be mobile or it may be stationary. Suitable
containers include, but are not limited to, frac tanks (see FIGS.
5A-5C). For example, a suitable container 444, 544 is available
from PCI Manufacturing, LLC. In an embodiment, the container 444,
544 may be an OPT FRAC, 500 BBL, S/E, CIRC Line frac tank from PCI
Manufacturing, LLC.
[0301] Alternatively, the container 444, 544 may be made of any
suitable corrosion-resistant material. The container 444, 544 may
be made of coated metals, corrosion-resistant metals or plastics.
Suitable coated metals include, but are not limited to,
plastic-coated carbon steel; suitable corrosion-resistant metals
include, but are not limited to, stainless steel, Hastelloy.RTM.
alloy, Monel.RTM. alloy and combinations thereof; and suitable
plastics include, but are not limited to, polyethylene,
polypropylene, polyvinyl chloride (PVC) and combinations thereof.
In an embodiment, the container 444, 544 may be made of
plastic-coated carbon steel. In an embodiment, the container 444,
544 may be made of Plasite 7159 HAR-coated carbon steel.
[0302] The container 444, 544 may be any suitable shape. Suitable
shapes include, but are not limited to, cylindrical, cubic, cuboid,
prism, pyramid, spherical and combinations thereof. In an
embodiment, the container 444, 544 may be approximately a cuboid
shape.
[0303] The demister element 448, 548 may be any suitable demister
element. The demister element 448, 548 may be made of any suitable
corrosion-resistant material. The demister element 448, 548 may be
made of any suitable corrosion-resistant metals or plastics. The
demister element 448, 548 may be made of metal or plastic mesh or
baffled, torturous-path chevron-type plates. Suitable metal mesh
includes, but is not limited to, stainless steel, Hastelloy.RTM.
alloy, Monel.RTM. alloy and combinations thereof; suitable plastic
mesh includes, suitable plastic mesh includes, but are not limited
to, chlorinated polyvinyl chloride (CPVC) polymers, fiberglass
reinforced plastic (FRP), Kynar.RTM. polyvinylidene fluoride (PVDF)
polymers, polyethylene polymers, polypropylene polymers, polyvinyl
chloride (PVC) polymers, Teflon.RTM. perfluoroalkoxy (PFA)
polymers, Teflon.RTM. polytetrafluroethylene (PTFE) polymers, and
combinations thereof; and suitable chevron-type plates include, but
are not limited to, polyethylene, polypropylene, polyvinylchloride
(PVC), stainless steel, Teflon.RTM. perfluoroalkoxy (PFA) polymers,
Teflon.RTM. polytetrafluroethylene (PTFE) polymers. In an
embodiment, the demister element 448, 548 may be made of 316
stainless steel.
[0304] The demister element 448, 548 may be any suitable shape to
enclose an upper portion of the container 444, 544. Suitable shapes
include, but are not limited to, cylindrical, cubic, cuboid, prism,
pyramid, spherical, and portions and combinations thereof. In an
embodiment, the demister element 448, 548 may be a cuboid shape
about 4-feet wide by about 8-feet long and from about 3-inches to
about 12-inches thick (and any range or value there between). In an
embodiment, the demister element 448, 548 may be a cuboid shape
about 4-feet wide by about 8-feet long and from about 4-inches to
about 6-inches thick. As shown in FIG. 4, the demister element 448,
548 forms an upper portion of the cuboid shape of the container
444, 544.
[0305] The evaporated water outlet 450 comprises a plurality of
outlet pores (not shown) in the demister element 448, 548.
Recycle and Discharge System
[0306] The bottom of the container 444, 544 may be connected to a
second inlet to the first 3-way valve 416 via pipe 452, 552. The
outlet of the first 3-way valve 416 may be connected to the inlet
of the pump via pipe 418, 518. The outlet of the pump 420, 520 may
be connected to the inlet of the second 3-way valve 432, 532 via
pipe(s) 422, 426, 522, 526. A second outlet of the second 3-way
valve 432, 532 may be connected to the discharge outlet 458, 558
via pipe 454, 554.
[0307] The discharge outlet 458, 558 may be any suitable outlet
that can handle up to about 40 psi. Suitable discharge outlets
include, but are not limited to, a flange connection, cam-lock
fittings and hammer unions. In an embodiment, the discharge outlet
458, 558 is a flange connection (see FIGS. 5A-5D). The discharge
outlet 458, 558 permits connection to an external waste disposal
storage (e.g., tank, truck, pond). The discharge outlet 458, 558
may be connected to the external waste disposal storage via hose,
pipe or other means as customary in the art.
Alternate Air Blower, Spray System and Mist Arresting System
[0308] In an embodiment, the system 400, 500 may further comprise
an air blower system 434, 534, a spray system 440, 540 and a mist
arresting system 446, 546. The air blower system 434, 534 comprises
a plurality of air blowers 436', 436''; the spray system 440
comprises a plurality of spray nozzles 442', 442''; and the mist
arresting system 446 comprises a plurality of demister elements
448', 448'' and the container 444, 544.
[0309] A first outlet of a first air blower 436' may be fluidly
connected to a first blower inlet of the manifold 439, 539 opposed
to a first spray outlet of the manifold 439, 539; and a second
outlet of a second air blower 436'' may be fluidly connected to a
second blower inlet of the manifold 439, 539 opposite a second
spray outlet of the manifold 439, 539, and so on.
[0310] In an embodiment, each outlet of the plurality of air
blowers 436', 436'' may be connected to its corresponding blower
inlet of the manifold 439, 539 via tubing. In an embodiment, the
tubing may be made of 316 stainless steel. In an embodiment, the
tubing may be 3/8-inch tubing.
[0311] In an embodiment, the air blower system 534 may further
comprise an air heating system 586. The air heating system 586
comprises an air ducting plenum 588 and a heater 587 (see FIG. 5C).
In an embodiment, the air heating system 586 may further comprise a
first thermometer 590 to measure the temperature of inlet air
and/or a second thermometer 592 to measure the temperature of
outlet air (see FIGS. 5B-5C).
[0312] In an embodiment, each spray outlet of the manifold 439, 539
may be connected to its corresponding inlet of the spray nozzle
442, via tubing. In an embodiment, each spray outlet of the
manifold 439, 539 comprises about 4 to about 6 tubes (see FIGS.
5A-5B). In an embodiment, the tubing may be made of 316 stainless
steel. In an embodiment, the tubing may be 3/8-inch tubing.
[0313] Outlets of the plurality of spray nozzles 442', 442''
discharge water droplets inside the container 444, 544. An upper
portion or top side of the container 444, 544 is enclosed with the
plurality of demister elements 448', 448'' to retain the water
droplets inside the container 444, 544. The plurality of demister
elements 448', 448'' are secured to and supported by the container
444, 544 in a manner customary in the art.
[0314] At least some of the water droplets evaporate to form water
vapor. The water vapor passes through pores in the plurality of
demister elements 448', 448'' and out the evaporated water outlet
450. Any un-evaporated water is retained by the plurality of
demister elements 448', 448'' and falls to the sump (bottom) of the
container 444, 544.
[0315] The evaporated water outlet 450 comprises a plurality of
outlet pores (not shown) in the plurality of demister elements
448', 448''.
[0316] The plurality of air blowers 436', 436'' may be any suitable
air blowers. The plurality of air blowers 436', 436'' may be
automatic or manual. The plurality of air blowers 436', 436'' may
be electric or hydraulic (see FIG. 4A-4C). Suitable air blowers
include, but are not limited to, variable-speed air blowers. For
example, suitable plurality of air blowers 436', 436'' are
available from Curtec. In an embodiment, the plurality of air
blowers 436', 436'' are variable-speed air blowers capable of
moving from about 1 k to about 6 k CFM per blower from Curtec. In
an embodiment, the plurality of air blowers 436', 436'' are
variable-speed air blowers capable of moving from about 1 k to
about 35 k CFM total from Curtec. In an embodiment, the plurality
of air blowers 436', 436'' are variable-speed air blowers capable
of moving from about 3 k to about 18 k CFM total from Curtec. In an
embodiment, the plurality of air blowers 436', 436'' are
variable-speed air blowers capable of moving from about 15 k to
about 35 k CFM total from Curtec.
[0317] The plurality of spray nozzles 442', 442'' may be any
suitable spray nozzles. Suitable plurality of spray nozzles
include, but are not limited to, rotary atomizers. For example, a
suitable plurality of spray nozzles 442', 442'' are available from
Ledebuhr Industries. In an embodiment, the plurality of spray
nozzles 442', 442'' are variable-speed rotary atomizers from
Ledebuhr Industries. In an embodiment, the rotary atomizers are
capable of high flow. In an embodiment, the rotary atomizers have a
plurality of spray heads. In an embodiment, the rotary atomizers
are capable of about 8 GPM flow per spray head. In an embodiment,
the spray heads are positioned at the discharge point of the air
blower. Alternatively, the spray heads are positioned inside the
container.
[0318] The plurality of spray nozzles 442', 442'' may be made of
any suitable corrosion-resistant material. The plurality of spray
nozzles 442', 442'' may be made of any suitable corrosion-resistant
metals. Suitable corrosion-resistant metals include, but are not
limited to, stainless steel, Hastelloy.RTM. alloy, Monel.RTM. alloy
and combinations thereof. In an embodiment, the plurality of spray
nozzles 442', 442'' (spray heads) are made of 316 stainless
steel.
[0319] The plurality of demister elements 448', 448'' may be any
suitable demister elements. The plurality of demister elements
448', 448'' may be made of any suitable corrosion-resistant
material. The plurality of demister elements 448', 448'' may be
made of metal or plastic mesh or baffled, torturous path
chevron-type plates. Suitable metal mesh includes, but is not
limited to, stainless steel, Hastelloy.RTM. alloy, Monel.RTM. alloy
and combinations thereof; suitable plastic mesh includes, suitable
plastic mesh includes, but are not limited to, chlorinated
polyvinyl chloride (CPVC) polymers, fiberglass reinforced plastic
(FRP), Kynar.RTM. polyvinylidene fluoride (PVDF) polymers,
polyethylene polymers, polypropylene polymers, polyvinyl chloride
(PVC) polymers, Teflon.RTM. perfluoroalkoxy (PFA) polymers,
Teflon.RTM. polytetrafluroethylene (PTFE) polymers, and
combinations thereof; and suitable chevron-type plates include, but
are not limited to, polyethylene, polypropylene, polyvinylchloride
(PVC), stainless steel, Teflon.RTM. perfluoroalkoxy (PFA) polymers,
Teflon.RTM. polytetrafluroethylene (PTFE) polymers. In an
embodiment, the plurality of demister elements 448', 448'' are made
of 316 stainless steel.
[0320] In an embodiment, the demister element 448, 548 may be about
4-inches to about 12-inches thick (and any range or value there
between). In an embodiment, the demister element 448, 548 may be
about 4-inches to about 6-inches thick. In an embodiment, the
demister element 448, 548 may be about 4-feet wide by about 8-feet
long.
Optional Shut-Off Valves
[0321] In an embodiment, the system 400, 500 may further comprise
an optional shut-off valve 406, 506 and an optional discharge
shut-off valve (not shown). The shut-off valve 406, 506 is disposed
in the pipe 408, 508, connecting the water inlet 404, 504 to the
first inlet of the first 3-way valve 416. The optional discharge
shut-off valve is disposed in the pipe 454, 554, connecting an
outlet of the second 3-way valve 432, 532 to the discharge outlet
458, 558.
[0322] The shut-off valve 406, 506 and the discharge shut-off valve
may be any suitable shut-off valve. The shut-off valve 406, 506 and
the optional discharge shut-off valve may be automatic or manual.
Suitable shut-off valves include, but are not limited to, ball
valves and butterfly valves. For example, a suitable shut-off valve
406, 506 is available from GF Piping Systems. In an embodiment, the
shut-off valve 406, 506 may be a Georg Fischer Type 563 Butterfly
Valve.
[0323] In an embodiment, the shut-off valve 406, 506 may have
2-inch connections.
[0324] The shut-off valve 406, 506 and the optional discharge shut
off valve may be made of any suitable corrosion-resistant material.
The shut-off valve 406, 506 and optional discharge shut-off valve
may be made of any suitable corrosion-resistant metals or plastics.
Suitable metals include, but are not limited to, plastic-coated
carbon steel, stainless steel, Hastelloy.RTM. alloy, Monel.RTM.
alloy and combinations thereof and suitable plastics include, but
are not limited to, ethylene propylene diene monomer (EPDM) rubber,
polyvinylchloride (PVC) and combinations thereof. In an embodiment,
the shut-off valve 406, 506 (wetted components) may be made of
polyvinyl chloride (PVC) and ethylene propylene diene monomer
(EPDM) rubber.
Optional Basket Strainer
[0325] In an embodiment, the system 400, 500 may further comprise a
basket strainer 424, 524 and an optional pressure sensor 425, 525.
An inlet of the basket strainer 424, 524 may be fluidly connected
to an outlet of pipe 422, 522, and an outlet of the basket strainer
424, 524 may be fluidly connected to an inlet of pipe 426, 526. In
an embodiment, the first pressure sensor 425 may be fluidly
connected to either the pipe 422, 522 or the inlet of the basket
strainer 424, 524. The basket strainer 424, 524 retains debris in
the water feed to prevent clogging of the spray nozzles 442.
[0326] The basket strainer 424, 524 may be any suitable basket
strainer. A suitable basket strainer 424, 524 includes, but is not
limited to, 1/16-inch perforated baskets, contained within a
simplex or duplex housing. For example, a suitable basket strainer
424, 524 is available from Hayward or Rosedale. In an embodiment,
the basket strainer 424, 524 may be a 1/16-inch perforated basket
from Hayward or Rosedale.
[0327] The basket strainer 424, 524 may be made of any suitable
corrosion-resistant material. The basket strainer 424, 524 may be
made of any suitable corrosion-resistant metals. The basket
strainer 424, 524 may be any suitable metal or plastic basket
strainer. Suitable metals include, but are not limited to,
stainless steel, Hastelloy.RTM. alloy, Monel.RTM. alloy and
combinations thereof; and suitable plastics include, but are not
limited to, chlorinated polyvinyl chloride (CPVC) polymers,
Kynar.RTM. polyvinylidene fluoride (PVDF) polymers, polyvinyl
chloride (PVC) polymers, Teflon.RTM. perfluoroalkoxy (PFA)
polymers, Teflon.RTM. polytetrafluroethylene (PTFE) polymers, and
combinations thereof. In an embodiment, the basket strainer 424,
524 (basket) may be made of 316 stainless steel.
[0328] The optional pressure sensor 425 may be any suitable
pressure sensor. For example, a suitable pressure sensor 425 is
available from Rosemount, Inc. In an embodiment, the pressure
sensor 425 may be a Rosemount 2088 Absolute and Gage Pressure
Transmitter from Rosemount, Inc.
Optional Sensors and Meters
[0329] In an embodiment, the system 400, 500 may further comprise a
first conductivity meter 410, 510, a first flow meter 412, 512
and/or a hygrometer 414, 514. The first conductivity meter 410, 510
and the flow meter 412, 512 may be fluidly connected to pipe 408,
508. The first conductivity meter 410, 510 monitors the
conductivity of the inlet or condensed wastewater from the external
wastewater source; and the first flow meter 412, 512 measures the
flow rate of the inlet wastewater or condensed water.
[0330] The first conductivity meter 410, 510 may be any suitable
conductivity meter. For example, a suitable first conductivity
meter 410, 510 is available from Mettler-Toledo AG or Advanced
Sensor Technologies, Inc. (ASTI). In an embodiment, the first
conductivity meter 410, 510 may be an InPro 7100 Series
Conductivity Sensor from Mettler-Toledo AG electrically connected
to a Multiparameter Transmitter M400 from Mettler-Toledo AG. In an
embodiment, the first conductivity meter 410, 510 may be a Model
ASTX-37PP-PT1000-20-TL-1056 Toroidal Conductivity Sensor from ASTI
electrically connected to a Model 1056-01-21-32-AN Dual Channel
Transmitter from ASTI.
[0331] The hygrometer 414 is fluidly exposed to ambient air near
system 400. The hygrometer 414 measures barometric pressure,
humidity and temperature of the ambient air near the system
400.
[0332] The hygrometer 414 may be any suitable hygrometer. For
example, a suitable hygrometer is available from Yankee
Environmental Systems, Inc. In an embodiment, the hygrometer 414
may be a Metrological Thermo-Hygrometer Model PTU-2000 from Yankee
Environmental Systems, Inc.
[0333] The first flow meter 412, 512 may be any suitable flow
meter. Suitable first flow meters include, but are not limited to,
magnetic, paddlewheel, ultrasonic vortex and insertion-type vortex
flow meters. For example, a suitable first flow meter 412, 512 is
available from Mettler-Toledo Thornton, Inc. In an embodiment, the
first flow meter 412, 512 may be a Model 8030 from Mettler-Toledo
Thornton, Inc. electrically connected to a Multiparameter
Transmitter M400 from Mettler-Toledo AG.
[0334] In an embodiment, the system 400, 500 may further comprise a
second conductivity meter 428, 528 and a pH meter 430, 530. The
second conductivity meter 428, 528 may be fluidly connected to pipe
426, 526; and the pH meter 430 may be fluidly connected to pipe
426, 526. The second conductivity meter 428, 528 monitors the
conductivity of the wastewater; and the pH meter 430 measures the
pH of the wastewater.
[0335] The second conductivity meter 428, 528 may be any suitable
conductivity meter. For example, a suitable second conductivity
meter 428, 528 is available from Mettler-Toledo AG or Advanced
Sensor Technologies, Inc. (ASTI). In an embodiment, the second
conductivity meter 428, 528 may be an InPro 7100 Series
Conductivity Sensor from Mettler-Toledo AG electrically connected
to a Multiparameter Transmitter M400 from Mettler-Toledo AG. In an
embodiment, the first conductivity meter 410, 510 may be a Model
ASTX-37PP-PT1000-20-TL-1056 Toroidal Conductivity Sensor from ASTI
electrically connected to a Model 1056-01-21-32-AN Dual Channel
Transmitter from ASTI. In an embodiment, the first conductivity
meter 410, 510 and the second conductivity meter 428, 528 may be
the same type.
[0336] The pH meter 430 may be any suitable pH meter. For example,
a suitable pH meter 430 is available from Mettler-Toledo AG or
Advanced Sensor Technologies, Inc. (ASTI). In an embodiment, the pH
meter 430 may be an InPro 3300 Non-Glass Electrode for pH Measuring
Systems from Mettler-Toledo AG electrically connected to a
Multiparameter Transmitter M400 from Mettler-Toledo AG. In an
embodiment, the pH meter 430 may be a Model PNGR
8951-1000-20-TL-WPB Submersible Saturated Brine Resistant pH Sensor
from ASTI electrically connected to a Model 1056-01-21-32-AN Dual
Channel Transmitter from ASTI.
[0337] In an embodiment, the system 400 may further comprise a
differential pressure sensor 445. The differential pressure sensor
445 measures the pressure drop across the demister element 448, 548
or the plurality of demister elements 448', 448''.
[0338] The differential pressure sensor 445 may be any suitable
differential pressure sensor. For example, a suitable differential
pressure sensor 445 is available from Dwyer Instruments Inc. In an
embodiment, the differential pressure sensor 445 may be a Series
3000 Photohelic Differential Pressure Gage from Dwyer Instruments
Inc.
[0339] In an embodiment, the system 400, 500 may further comprise a
second flow meter 456, 556. The second flow meter 456, 556 may be
fluidly connected to pipe 454, 554. The second flow meter 456, 556
measures the flow rate of the discharge waste.
[0340] The second flow meter 456, 556 may be any suitable flow
meter. Suitable second flow meters include, but are not limited to,
magnetic, paddlewheel, ultrasonic vortex and insertion-type vortex
flow meters. For example, a suitable second flow meter 456, 556 is
available from Mettler-Toledo Thornton, Inc. In an embodiment, the
second flow meter 456, 556 may be a Model 8030 from Mettler-Toledo
Thornton, Inc. electrically connected to a Multiparameter
Transmitter M400 from Mettler-Toledo AG.
Optional Limit/Level Switches
[0341] In an embodiment, the system 400 may further comprise a
high-water level switch (not shown) and/or a low-water level switch
(not shown).
The high-water level and the low-water level switches may be any
suitable water level switches. For example, the high-water level
and the low-water level switches are available from Magnetrol
International Inc. In an embodiment, the high-water level and the
low-water level switches are C24, C25 Boiler and Water Column
Liquid Level Switches from Magnetrol International Inc.
Optional Acid Conditioning System
[0342] In an embodiment, the system 400 may further comprise an
acid conditioning system 460. The acid conditioning system 460
comprises an acid tote 462 and an acid metering pump 466.
[0343] The acid may be any suitable acid. Suitable acids include,
but are not limited to, hydrochloric acid and sulfuric acid. In an
embodiment, the acid may be hydrochloric acid (20 baume). In an
embodiment, the acid may be sulfuric acid (98%). In an embodiment,
the desired pH of the wastewater is about 6.5 or below to minimize
calcium carbonate scaling. In an embodiment, the amount of acid
solution added varies, depending on inlet water conditions (e.g.,
pH, alkalinity).
[0344] An outlet of the acid tote 462 may be fluidly connected to
an inlet of the acid metering pump 466 via tubing 464; and an
outlet of the acid metering pump 466 may be fluidly connected to
pipe 422, 522 via tubing 472.
[0345] The acid tote 462 may be any suitable acid tote or other
bulk chemical storage unit. Suitable acid totes include, but are
not limited to, an industry standard shipping tote. For example, a
suitable acid tote 462 is available from National Tank Outlet. In
an embodiment, the acid tote 462 may be a 275 gallon or a 330
gallon industry standard shipping tote.
[0346] The acid metering pump 466 may be any suitable acid metering
pump. Suitable acid metering pumps include, but are not limited to,
peristaltic pumps. For example, a suitable acid metering pump 466
is available from Blue-White Industries, Inc., Cole Palmer
Instrument Company and Watson Marlow. In an embodiment, the acid
metering pump 466 may be a self-priming peristaltic pump from
Blue-White Industries, Inc.
[0347] The tubing 464, 472 may be made of any suitable
corrosion-resistant tubing. The tubing 464, 472 may be made of any
suitable corrosion-resistant metals or plastics. Suitable metals
include, but are not limited to, AL-6XN alloy, Hastelloy.RTM.
alloy, Monel.RTM. alloy and combinations thereof; and suitable
plastics include, but are not limited to, chlorinated polyvinyl
chloride (CPVC) polymers, fiberglass reinforced plastic (FRP),
Kynar.RTM. polyvinylidene fluoride (PVDF) polymers, polyethylene
polymers, polypropylene polymers, polyvinyl chloride (PVC)
polymers, Teflon.RTM. perfluoroalkoxy (PFA) polymers, Teflon.RTM.
polytetrafluroethylene (PTFE) polymers, and combinations thereof.
For example, suitable tubing 464, 472 may be made of Teflon.RTM.
PFA or PTFE.
[0348] In an embodiment, the acid conditioning system 460 may
further comprise an acid flow meter 470. The acid flow meter 470
may be fluidly connected to tubing 472. The acid flow meter 470
measures the flow rate of the acid solution.
[0349] The acid flow meter 470 may be any suitable flow meter.
Suitable acid flow meters include, but are not limited to,
paddlewheel, ultrasonic vortex and insertion-type vortex flow
meters. For example, a suitable acid flow meter 470 is available
from ProMinent. In an embodiment, the acid flow meter 470 may be a
Model DulcoFlow DFMa from ProMinent with built-in signal
transmission capability.
Optional Bactericide Conditioning System
[0350] In an embodiment, the system 400 may further comprise a
bactericide conditioning system 474. The bactericide conditioning
system 474 comprises a bactericide tote 476 and a bactericide
metering pump 480.
[0351] The bactericide may be any suitable bactericide. Suitable
bactericide includes, but is not limited to, bleach, bromine,
chlorine dioxide (generated), 2,2-dibromo-3-nitrilo-propionade
(DBNPA), glutaraldehyde, isothiazolin (1.5%) and ozone (generated).
In an embodiment, the bactericide may be selected from the group
consisting of bleach (12.5%), bromine, chlorine dioxide
(generated), DBNPA (20%), glutaraldehyde (50%), isothiazolin (1.5%)
and ozone (generated). In an embodiment, the desired bactericide
concentration is from about 10 ppm to about 1000 ppm (and any range
or value there between). The amount of bactericide solution added
to the wastewater varies, depending on inlet water condition.
[0352] An outlet of the bactericide tote 476 may be fluidly
connected to an inlet of the bactericide metering pump 480 via
tubing 478; and an outlet of the bactericide metering pump 480 may
be fluidly connected to pipe 422, 522 via tubing 482.
[0353] The bactericide tote 476 may be any suitable bactericide
tote or other bulk chemical storage unit. Suitable bactericide
totes include, but are not limited to, an industry standard
shipping tote. For example, a suitable bactericide tote 476 is
available from National Tank Outlet. In an embodiment, the
bactericide tote 476 may be a 275 gallon or 330 gallon industry
standard shipping tote.
[0354] In an alternative embodiment, the bactericide tote 476 may
be replaced with a suitable bactericide generating apparatus (not
shown). For example, a suitable bactericide apparatus is available
from Miox Corporation. In an embodiment, the bactericide generating
apparatus (not shown) may be a Model AE-8 from Miox
Corporation.
[0355] The bactericide metering pump 480 may be any suitable
bactericide metering pump. Suitable bactericide metering pumps
include, but are not limited to, peristaltic pumps. For example, a
suitable bactericide metering pump 480 is available from Blue-White
Industries, Inc., Cole-Palmer Instrument Company and Watson Marlow.
In an embodiment, the bactericide metering pump 480 may be a
self-priming peristaltic pump from Blue-White Industries, Inc.
[0356] The tubing 478, 482 may be made of any suitable
corrosion-resistant tubing. The tubing 478, 482 may be any suitable
metal or plastic. Suitable metals include, but are not limited to,
AL-6XN alloy, Hastelloy.RTM. alloy, Monel.RTM. alloy and
combinations thereof; and suitable plastics include, but are not
limited to, chlorinated polyvinyl chloride (CPVC) polymers,
fiberglass reinforced plastic (FRP), Kynar.RTM. polyvinylidene
fluoride (PVDF) polymers, polyethylene polymers, polypropylene
polymers, polyvinyl chloride (PVC) polymers, Teflon.RTM.
perfluoroalkoxy (PFA) polymers, Teflon.RTM. polytetrafluroethylene
(PTFE) polymers, and combinations thereof. In an embodiment, the
tubing 478, 482 may be made of Teflon.RTM. PFA or PTFE.
[0357] In an embodiment, the bactericide conditioning system 474
may further comprise a bactericide flow meter 484. The bactericide
flow meter 484 may be fluidly connected to tubing 482. The
bactericide flow meter 484 measures the flow rate of the
bactericide solution.
[0358] The bactericide flow meter 484 may be any suitable flow
meter. Suitable bactericide flow meters include, but are not
limited to, paddlewheel, ultrasonic vortex and insertion-type
vortex flow meters. For example, a suitable bactericide flow meter
484 is available from ProMinent. In an embodiment, the bactericide
flow meter 484 may be a Model DulcoFlow DFMa from ProMinent with
built-in signal transmission capability.
Second Alternative Embodiment
[0359] A schematic of a second exemplary system 1000 for spray
evaporation of water according to another embodiment of the present
invention is shown in FIGS. 10A-10C and 11A-11F. The system 1000,
1100 comprises a wastewater inlet 1004, a pump 1018, a first air
blower 1042, a first manifold 1028, a drip orifice 1038, a
container 1039, a demister element 1045, and a discharge outlet
1076.
[0360] In an embodiment, the system 1000, 1100 is capable of
evaporating between about 30 to about 100 barrels of wastewater per
day (i.e., about 950 to about 3170 gallons per day). In an
embodiment, the system 1000, 1100 is capable of evaporating between
about 30 to about 60 barrels of wastewater per day (i.e., about 950
to about 1900 gallons per day). (see FIGS. 10A-10B). If a higher
throughput is desired, a plurality of system 1000, 1100 may be used
in parallel to treat the wastewater.
[0361] The wastewater inlet 1004 may be any suitable wastewater
inlet that can handle up to about 40 psi. Suitable wastewater
inlets include, but are not limited to, flange connections,
cam-lock fittings and hammer unions. In an embodiment, the
wastewater inlet 1004 is a hammer union connection (see FIGS.
10A-10B). The wastewater inlet 1004 permits connection to an
external wastewater source via a wastewater suction header 1002.
The water inlet 1004 may be connected to the external wastewater
source via a hose, pipe or other means customary in the art.
Optional Pre-Treatment of Volatile Organic Carbons (VOCs) in
Wastewater
[0362] Some wastewater sources may contain volatile organic
compounds often measured and reported as volatile organic carbons
(VOCs). These VOCs may exceed air discharge limits under federal
and/or state environmental regulations and/or system 1000, 1100
limits due to potential temperature excursions.
[0363] If the VOC levels exceed air discharge limits and/or system
1000, 1100 limits, the VOCs may be reduced to acceptable levels or
removed from the wastewater source upstream of the wastewater inlet
1004 using a pretreatment method.
[0364] Any suitable pretreatment method may be used to
reduce/remove VOCs from wastewater. For example, a suitable
pretreatment method includes, but is not limited to, aeration of
the wastewater within a tank, stripping the wastewater in a packed
tower, flowing the wastewater through activated carbon, and
combinations thereof.
Inlet System
[0365] In an embodiment, the system 1000, 1100 may further comprise
a first (feed) shut-off valve 1006, a first (feed) valve 1012 and a
second (feed/recirculating) valve 1054. The wastewater inlet 1004
may be connected to an inlet of a first (feed) shut-off valve 1006
via a pipe 1008a.
[0366] An outlet of the first (feed) shut-off valve 1006 may be
connected to an inlet of the first (feed) valve 1012 via a pipe
1008a.
[0367] An outlet of the first (feed) valve 1012 may be connected to
an inlet of a pipe 1016b or an inlet of a pump 1018 via a pipe
1008b.
[0368] An outlet of pipe 1016b may be connected to an inlet of the
pump 1018 (and an outlet of a third (pump supply) valve 1055 may be
connected to an inlet of the pump 1018 via a pipe 1016b).
[0369] An outlet of the pump 1018 may be connected to an inlet of
the second (feed/recirculating) valve 1054 via pipe 1020a.
[0370] An outlet of the second (feed/recirculating) valve 1054 may
be connected to an inlet of a first manifold 1028 or a drip system
1034 via a pipe 1026a/1026b.
[0371] In an embodiment, the system 1000, 1100 may further comprise
a first (feed) shut-off valve 1006. The (feed) shut-off valve 1006
may be any suitable shut-off valve. Suitable first (feed) shut-off
valves 1006 include, but are not limited to, ball valves and
butterfly valves. For example, a suitable first (feed) shut-off
valve 1006 is available from GF Piping Systems. In an embodiment,
the first (feed) shut-off valve 1006 may be a GF Piping Systems
Type 546 Ball Valve from GF Piping Systems. In an embodiment, the
first (feed) shut-off valve 1006 may be automatic or manual. In an
embodiment, the first (feed) shut-off valve 1006 may be normally
CLOSED.
[0372] In an embodiment, the first (feed) shut-off valve 1006 may
have 2-inch connections.
[0373] In an embodiment, the system 1000, 1100 may further comprise
a first (feed) valve 1012 and a second (feed/recirculating) valve
1054. The first (feed) valve 1012 and the second
(feed/recirculating) valve 1054 may be any suitable switching
valve. Suitable first (feed) valve 1012 and second
(feed/recirculating) valve 1054 include, but are not limited to,
ball valves. For example, a suitable first (feed) valve 1012 and
second (feed/recirculating) valve 1054 is available from GF Piping
Systems. In an embodiment, the first (feed) valve 1012 and the
second (feed/recirculating) valve 1054 may be a GF Piping System
Type 546 Electric Actuated Ball Valve from GF Piping Systems. In an
embodiment, the first (feed) valve 1012 and the second
(feed/recirculating) valve 1054 may be automatic or manual. In an
embodiment, the first (feed) valve 1012 and the second
(feed/recirculating) valve 1054 may be electric or pneumatic
actuation. In an embodiment, the first (feed) valve 1012 and the
second (feed/recirculating) valve 1054 may be normally CLOSED.
[0374] In an embodiment, the first (feed) valve 1012 and the second
(feed/recirculating) valve 1054 may have 2-inch connections.
[0375] The first (feed) shut-off valve 1006, the first (feed) valve
1012 and the second (feed/recirculating) valve 1054 may be made of
any suitable corrosion-resistant material. The first (feed)
shut-off valve 1006, the first (feed) valve 1012 and the second
(feed/recirculating) valve 1054 may be made of any suitable
corrosion-resistant metals or plastics. Suitable metals include,
but are not limited to, plastic-coated carbon steel, stainless
steel, Hastelloy.RTM. alloy, Monel.RTM. alloy and combinations
thereof; and suitable plastic include, but are not limited to,
polyvinylchloride (PVC) polymers, chlorinated polyvinyl chloride
(CPVC) polymers, fiberglass reinforced plastic (FRP), Kynar.RTM.
polyvinylidene fluoride (PVDF) polymers, polyethylene polymers,
polypropylene polymers, Teflon.RTM. perfluoroalkoxy (PFA) polymers,
Teflon.RTM. polytetrafluroethylene (PTFE) polymers, and
combinations thereof. In an embodiment, the first (feed) shut-off
valve 1006, the first (feed) valve 1012 and the second
(feed/recirculating) valve 1054 (wetted components) may be made of
polyvinyl chloride (PVC) and ethylene propylene diene monomer
(EPDM) rubber.
[0376] In an embodiment, the system 1000, 1100 may further comprise
an optional first limit switch (not shown) and an optional second
limit switch (not shown). (See e.g., FIGS. 1A-1B: 113 & 114).
In an embodiment, the first limit switch confirms that the first
(feed) valve 1012 is OPEN; and the second limit switch confirms
that the first (feed) valve 1012 is CLOSED.
[0377] In an embodiment, the system 1000, 1100 may further comprise
an optional third limit switch (not shown) and an optional fourth
limit switch (not shown). (See e.g., FIGS. 1A-1B: 113 & 114).
In an embodiment, the third limit switch confirms that the second
(feed/recirculating) valve 1054 is OPEN; and the fourth limit
switch confirms that the second (feed/recirculating) valve 1054 is
CLOSED.
[0378] The pump 1018 may be any suitable pump. Suitable pumps 1018
include, but are not limited to, centrifugal pumps. For example, a
suitable pump 1018 is available from MP Pumps Inc. In an
embodiment, the pump 1018 may be a FLOMAX.RTM. 8 Self-Priming
Centrifugal Pump from MP Pumps Inc. In an embodiment, the pump 1018
may be about 1 to about 3 HP centrifugal pump. In an embodiment,
the pump 1018 may be about a 1.5 HP variable speed pump.
[0379] In an embodiment, the pump 1018 may have 2-inch
connections.
[0380] The pump 1018 may be made of any suitable
corrosion-resistant material. The pump 1018 may be made of any
suitable corrosion-resistant metals or plastics. Suitable metals
include, but are not limited to, cast iron, stainless steel,
super-duplex stainless steel, AL-6XN alloy, Ni-Al-Brz alloy,
Hastelloy.RTM. alloy, Monel.RTM. alloy and combinations thereof;
and suitable plastics include, but are not limited to, chlorinated
polyvinyl chloride (CPVC) polymers, fiberglass reinforced plastic
(FRP), Kynar.RTM. polyvinylidene fluoride (PVDF) polymers,
polyethylene polymers, polypropylene polymers, polyvinyl chloride
(PVC) polymers, Teflon.RTM. perfluoroalkoxy (PFA) polymers,
Teflon.RTM. polytetrafluroethylene (PTFE) polymers, and
combinations thereof. For example, the pump 1018 (wetted
components) may be made of stainless steel, super-duplex stainless
steel, AL-6XN alloy, Ni-Al-Brz alloy, Hastelloy.RTM. alloy,
Monel.RTM. alloy or FRD. In an embodiment, the pump 1018, including
internal wetted components, was made of 316 stainless steel. In an
embodiment, the pump 1018 may be made of cast iron if a shorter
service life is acceptable.
[0381] The pipe 1008a, 1008b, 1016a, 1016b, 1020a, 1026a, 1026b may
be made of any suitable corrosion-resistant pipe. The pipe 1008a,
1008b, 1016a, 1016b, 1020a, 1026a, 1026b may be any suitable
corrosion-resistant metals or plastics. Suitable metals include,
but are not limited to, plastic-coated carbon steel, stainless
steel, super-duplex stainless steel, AL-6XN alloy, Ni-Al-Brz alloy,
Hastelloy.RTM. alloy, Monel.RTM. alloy and combinations thereof;
and suitable plastics include, but are not limited to, chlorinated
polyvinyl chloride (CPVC) polymers, fiberglass reinforced plastic
(FRP), Kynar.RTM. polyvinylidene fluoride (PVDF) polymers,
polyethylene polymers, polypropylene polymers, polyvinyl chloride
(PVC) polymers, Teflon.RTM. perfluoroalkoxy (PFA) polymers,
Teflon.RTM. polytetrafluroethylene (PTFE) polymers, and
combinations thereof. In an embodiment, the pipe 1008a, 1008b,
1016a, 1016b, 1020a, 1026a, 1026b may be made of plastic-coated
carbon steel. In an embodiment, the pipe 1008a, 1008b, 1016a,
1016b, 1020a, 1026a, 1026b may be made of Plasite 7159 HAR-coated
carbon steel. In an embodiment, the pipe 1008a, 1008b, 1016a,
1016b, 1020a, 1026a, 1026b may be made of 316 stainless steel.
[0382] In an embodiment, the pipe 1008a, 1008b, 1016a, 1016b,
1020a, 1026a, 1026b may be 2-inch pipe.
Container and Demister Elements
[0383] In an embodiment, the system 1000, 1100 may further comprise
a container 1039 and a demister element 1045.
[0384] The container 1039 may be any suitable container. The
container 1039 may be mobile or it may be stationary. Suitable
containers 1039 include, but are not limited to, tanks (see FIG.
10A-10B). In an embodiment, the container 1039 may be an upright
cylinder sealed to a plate or a skid. In an embodiment, the
container 1039 may be a culvert sealed to a plate or a skid
(discussed below).
[0385] In an embodiment, the container 1039 may be any suitable
size (e.g., diameter and height).
[0386] In an embodiment, the container 1039 may be any suitable
diameter. For example, a suitable diameter may be from about 4 feet
to about 15 feet, and any range or value there between. In an
embodiment, the diameter may be about 4 feet.
[0387] In an embodiment, the container 1039 may be any suitable
height. For example, a suitable height may be from about 8feet to
about 12 feet, and any range or value there between. In an
embodiment, the height may be about 12 feet.
[0388] In an embodiment, an upper portion of the container 1039 may
be lowered and/or removed to reduce the travel height to up to
about 12 feet.
[0389] Alternatively, the container 1039 may be made of any
suitable corrosion-resistant material. The container 1039 may be
made of coated metal, corrosion-resistant metals or plastics.
Suitable coated metals include, but are not limited to,
epoxy-coated carbon steels, plastic-coated carbon steels, and
combinations thereof; suitable corrosion-resistant metals include,
but are not limited to, stainless steel, Hastelloy.RTM. alloy,
Monel.RTM. alloy, and combinations thereof; and suitable plastics
include, but are not limited to, polyethylene, polypropylene,
polyvinyl chloride (PVC), and combinations thereof. In an
embodiment, the container 1039 may be made of epoxy-coated carbon
steel and/or plastic-coated carbon steel. In an embodiment, the
container 1039 may be made of Plasite 7159 HAR-coated carbon
steel.
[0390] The container 1039 may be any suitable shape. Suitable
shapes include, but are not limited to, cylindrical, cubic, cuboid,
prism, pyramid, spherical and combinations thereof. In an
embodiment, the container 1039 may be approximately a cylindrical
shape.
[0391] The demister element 1045 may be any suitable demister
element. Suitable demister elements 1045 include, but are not
limited to, crossflow cellular drift eliminators (see FIGS. 2A-2F).
For example, a suitable demister element 1045 is available from
Brentwood Industries, Inc. In an embodiment, the demister element
1045 may be an Accu-Pac.RTM. Crossflow Cellular Drift Eliminator
from Brentwood Industries, Inc.
[0392] Alternatively, the demister element 1045 may be made of any
suitable corrosion-resistant material. The demister element 1045
may be any suitable corrosion-resistant metals or plastics. The
demister element 1045 may be made of metal or plastic mesh or
baffled, torturous-path chevron-type plates. Suitable metal mesh
includes, but is not limited to, stainless steel, Hastelloy.RTM.
alloy, Monel.RTM. alloy and combinations thereof; suitable plastic
mesh includes, but are not limited to, chlorinated polyvinyl
chloride (CPVC) polymers, fiberglass reinforced plastic (FRP),
Kynar.RTM. polyvinylidene fluoride (PVDF) polymers, polyethylene
polymers, polypropylene polymers, polyvinyl chloride (PVC)
polymers, Teflon.RTM. perfluoroalkoxy (PFA) polymers, Teflon.RTM.
polytetrafluroethylene (PTFE) polymers, and combinations thereof;
and suitable chevron-type plates include, but are not limited to,
polyethylene, polypropylene, polyvinylchloride (PVC), stainless
steel, Teflon.RTM. perfluoroalkoxy (PFA) polymers, Teflon.RTM.
polytetrafluroethylene (PTFE) polymers. In an embodiment, the
demister element 1045 may be made of 316 stainless steel. In an
embodiment, the demister element 1045 may be made of PVC.
[0393] The demister element 1045 may be any suitable shape to
enclose an upper portion and/or a side portion of the container
1039. Suitable shapes include, but are not limited to, cylindrical,
cubic, cuboid, prism, pyramid, spherical, and portions and
combinations thereof. In an embodiment, the demister element 1045
(e.g., upper portion) may be a cylindrical cuboid from about 2-feet
diameter to about 16-feet diameter and from about 4-inches to about
12-inches thick (and any range or value there between).
[0394] As shown in FIGS. 10A-10B, the demister element 1045 forms
an upper portion of the cylindrical shape of the container 1039. In
an embodiment, the demister element 1045 (e.g., upper portion) may
be a cylindrical shape from about 4-feet diameter to about 16-feet
diameter and from about 4-inches thick to about 12-inches thick
(and any range or value there between).
[0395] In an embodiment, the demister element 1045 (e.g., side
portion) may be a cuboid shape about 2-feet wide by about 13-feet
long and from about 6-inches thick to about 12-inches thick (and
any range or value there between). In an embodiment, the demister
element 1045 (e.g., side portion) may be a cuboid shape about
2-feet wide by about 51-feet long and from about 4-inches thick to
about 12-inches thick (and any range or value there between).
[0396] The evaporated water outlet 1046 comprises a plurality of
outlet pores (not shown) in the demister element 1045.
[0397] During normal operations, the evaporated water (i.e.,
humidified air) may be discharged through the evaporated water
outlet 1046 in the demister element 1045 to ambient environment
(i.e., air).
[0398] Alternatively, the evaporated water (i.e., humidified air)
from the evaporated water outlet 1046 in the demister element 1045
may be collected and condensed for use in drilling or completion
operations, or collected and discharged to ambient environment
(e.g., pond) dependent provided the condensed water satisfies
environmental discharge limits.
[0399] In an embodiment, the evaporated water (i.e., humidified
air) from the evaporated water outlet 1046 in the demister element
1045 may be collected in a low pressure conduit. In an embodiment,
the evaporated water (i.e., humidified air) from the evaporated
water outlet 1046 in the demister element 1045 may be collected and
condensed in a low pressure conduit. In an embodiment, a portion of
the conduit may be cooled and/or refrigerated. In an embodiment, a
portion of the conduit may be cooled and/or refrigerated to a
temperature at or below a dew point temperature of water vapor at
the conduit pressure.
[0400] In an embodiment, an evaporated water (i.e., humidified air)
recovery method may be any suitable condensation or water recovery
method. For example, a suitable evaporated water recovery method,
includes but is not limited to, recovery of evaporated water by
condensation on a cooled or refrigerated surface that is at a
temperature at or below the dew point temperature of water vapor at
the conduit pressure.
[0401] In an embodiment, the system 1000, 1100 may further comprise
a container 1039 comprising a sump (bottom) of the container
1039.
[0402] In an embodiment, the system 1000, 1100 may further comprise
a first sacrificial anode (not shown) and a second sacrificial
anode (not shown) for galvanic cathode (corrosion) protection of
the container 1039. (See e.g., FIGS. 1A-1B: 197 & 198). The
first sacrificial anode and the second sacrificial anode may be
disposed in the sump (bottom) of the container 1039.
[0403] The first sacrificial anode (not shown) and the second
sacrificial anode (not shown) may be made of any suitable galvanic
anode material. (See e.g., FIGS. 1A-1B: 197 & 198). For
example, suitable galvanic anode materials include, but are not
limited to, aluminum, magnesium and zinc. In an embodiment, the
first sacrificial anode and the second sacrificial anode may be
made of aluminum and/or zinc.
Optional Post-Emissions Diffusers and Heaters
[0404] Under certain conditions, the evaporated water (i.e.,
humidified air) leaving the system 1000, 1100 may condense during
cold weather conditions, causing a visible water vapor plume.
[0405] In an embodiment, the evaporated water (i.e., humidified
air) may be heated (to raise the evaporated water temperature to
above the dew point) upstream of the evaporated water outlet 1046
in the demister element 1045. In an embodiment, the evaporated
water (i.e., humidified air) may be heated via addition of
preheated air upstream of the evaporated water outlet 1046 in the
demister element 1045.
[0406] In an embodiment, the evaporated water (i.e., humidified
air) may be heated (to raise the evaporated water temperature to
above the dew point) downstream of the evaporated water outlet 1046
in the demister element 1045. In an embodiment, the evaporated
water (i.e., humidified air) may be heated via addition of
preheated air downstream of the evaporated water outlet 1046 in the
demister element 1045.
[0407] In an embodiment, the system 1000, 1100 may further comprise
a duct, wherein preheated air from the air preheater 1043 is
directed into the container 1039 via the duct. In an embodiment,
the system 1000, 1100 further comprises a duct, wherein preheated
air from the air preheater 1043 is directed into the container 1039
at or near the evaporated water outlet 1046 in the demister element
1045 via the duct.
Optional Skid
[0408] In an embodiment, the system 1000, 1100 may further comprise
a skid 110018. (See e.g., FIGS. 11A-11F). The system 1000, 1100 may
be constructed on the skid 110018 designed to enable rapid, safe
loading, transportation and unloading of equipment in both the
factory and the field. In an embodiment, the skid 110018 may use an
integral forklift pocket to enable safe handling by a forklift,
and, after being unloaded from a trailer or a truck, the skid
110018 is strong enough to sit directly on unimproved ground. This
enables rapid and safe loading and unloading with a minimum of
equipment such as a forklift or a winch truck which are commonly
available in the oilfield.
[0409] In various embodiments, the skid 110018 may include
features, such as: [0410] structural supports for process piping
and equipment [0411] grates for safe all-weather walking and access
to equipment [0412] vibration isolation for generators and other
process equipment [0413] antennae masts for satellite, radio or
cellular signaling equipment [0414] structural support for
electrical control and instrumentation equipment
[0415] In an embodiment, the system 1000, 1100 including the skid
110018 may be any suitable size (i.e., height, length and
width).
[0416] In an embodiment, the system 1000, 1100 including the
container 1039 may be any suitable height. For example, a suitable
height may be up to about 12 feet or even higher, and any range or
value there between. In an embodiment, the height may be about 12
feet.
[0417] In an embodiment, an upper portion of the system 1000, 1100
including the container 1039 may be lowered and/or removed to
enhance portability. In an embodiment, the upper portion of the
system 1000, 1100 including the container 1039 may be lowered
and/or removed to reduce the travel height to up to about 12 feet.
The height of up to about 12 feet allows the system 1000, 1100 to
be moved under most "low clearance" bridges and overpasses thereby
avoiding time consuming alternative routes to bypass the low
clearance bridges and overpasses. Further, the height of up to
about 12 feet allows the system 1000, 1100 to be moved over most
roads without a permit thereby reducing transportation cost and
enabling the system 1000, 1100 to access areas a permit load cannot
reach. The ability to lower and/or remove the upper portion of the
system 1000, 1100 including the container 1039 decreases the travel
height of the system 1000, 1100 below the height where a permit
would be required.
[0418] In an embodiment, the system 1000, 1100 may be any suitable
length. For example, a suitable length may be up to about 12 feet,
and any range or value there between. In an embodiment, the length
of the system 1000, 1100 may be 12 feet.
[0419] In an embodiment, the system 1000, 1100 may be any suitable
width. For example, a suitable width may be up to about 8 foot six
inches, and any range or value there between. In an embodiment, the
width may be about 8feet six inches.
[0420] The width of up to about 8 foot 6 inch allows the system
1000, 1100 to be moved over most roads without a permit thereby
reducing transportation cost and enabling the system 1000, 1100 to
access areas a permit load cannot reach.
[0421] The skid may be made of any suitable corrosion-resistant
material. The skid may be made of coated metal or
corrosion-resistant metals. Suitable coated metals include, but are
not limited to, epoxy-coated carbon steels, plastic-coated carbon
steels, and combinations thereof; suitable corrosion-resistant
metals include, but are not limited to, stainless steels, and
combinations thereof. In an embodiment, the skid may be made of
epoxy-coated carbon steel and/or plastic-coated carbon steel.
Optional Trailer or Truck
[0422] In an embodiment, the system 1000, 1100 may further comprise
a skid 110018 mounted on or removeably secured to a trailer or a
truck.
Optional Integrated Containment
[0423] In an embodiment, the system 1000, 1100 may further comprise
a skid 110018. The system 1000 may be constructed on the skid
110018 designed to enable rapid, safe loading, transportation and
unloading of equipment in both the factory and the field. In an
embodiment, the skid 110018 may use an integral forklift pocket to
enable safe handling by a forklift, and, after being unloaded from
a trailer or a truck, the skid 110018 is strong enough to sit
directly on unimproved ground. This enables rapid and safe loading
and unloading with a minimum of equipment such as a forklift or a
winch truck which are commonly available in the oilfield.
[0424] For many installations, federal and/or state environmental
regulations require a leak proof containment to prevent potential
pollution of soil, streams or other water bodies in the event of a
leak or a malfunction. The leak proof containment must be sized to
accommodate all the process wastewater plus a safety factor. Common
methods of containment include earthen berms, waterproof membranes,
and impervious clay liners. These methods have a number of
drawbacks including a high capital cost, a potential for damage to
containment by equipment or burrowing animals, and a likelihood of
ground disruption from excavation and placement of a liner.
[0425] In an embodiment, the system 1000, 1100 may further comprise
an integrated containment system 110020 comprising a skid 110018
surrounded by a liner 110022. In an embodiment, the system 1000,
1100 may further comprise an integrated containment system 110020
comprising a skid 110018 surrounded by a factory-installed liner
110022.
[0426] The liner 110022 may be any suitable corrosion-resistant
material. The liner 110022 may be made of any coated metal or any
corrosion-resistant metals or plastics. Suitable coated metals
include, but are not limited to, epoxy-coated carbon steels,
fiberglass-coated carbon steels, plastic-coated carbon steels, and
combinations thereof; suitable corrosion-resistant metals include,
but are not limited to, stainless steels, and combinations thereof;
and suitable plastics include, but are not limited to, chlorinated
polyvinyl chloride (CPVC) polymers, fiberglass reinforced plastic
(FRP), Kynar.RTM. polyvinylidene fluoride (PVDF) polymers,
polyethylene polymers, polypropylene polymers, polyvinyl chloride
(PVC) polymers, Teflon.RTM. perfluoroalkoxy (PFA) polymers,
Teflon.RTM. polytetrafluoroethylene (PTFE) polymers, and
combinations thereof. In an embodiment, the liner 110022 may be
made of epoxy-coated carbon steel and/or plastic-coated carbon
steel. In an embodiment, the liner 110022 may be made of
fiberglass. In an embodiment, the liner 110022 may be made of
fiberglass-coated carbon steel.
[0427] Once installed, the liner 110022 will, inevitably, retain
not only process wastewater but also rain and snow melt. Because
that rain and snowmelt is collected in the liner 110022, the rain
and snow melt must be treated as process wastewater.
[0428] In an embodiment, the system 1000, 1100 may further comprise
a draw line.
[0429] An inlet of the draw line is disposed in the liner.
[0430] An outlet of the draw line may be fluidly connected to an
inlet of the pump 1018 to draw accumulated water from the liner
into the system 1000, 1100 for evaporation.
[0431] An outlet of the draw line may be fluidly connected to an
inlet of the container 1039 to draw accumulated water from the
liner into the system 1000, 1100 for evaporation.
[0432] This rain and snow melt is typically low in dissolved solids
and suspended solids, allowing very high rates of evaporation. The
ability to contain water and evaporate the water using the system
1000, 1100 represents a significant benefit in terms of cost,
reliability, and environmental impact.
Recirculation System
[0433] In an embodiment, the system 1000, 1100 may further comprise
a third (pump supply) valve 1055, and a draw line 1055a.
[0434] An inlet of the third (pump supply) valve 1055 may be
fluidly connected to the draw line 1055a and/or the first
(recirculating) outlet of the container 1039 at a first height of
the container 1039 via pipe 1016a.
[0435] An inlet of the draw line 1055a is fluidly disposed in a
sump (bottom of the container 1039.
[0436] An outlet of the draw line 1055a may be fluidly connected to
the first (recirculating) outlet of the container 1039 at the first
height of the container 1039. In an embodiment, the first height of
the container 1039 may be about 6 inches to about 4 feet (and any
range or value there between). In an embodiment, the first height
of the container 1039 may be from about 6 inches to about 1
foot.
[0437] An outlet of the third (pump supply) valve 1055 may be
connected to an inlet of the pump 1018 via pipe 1016b.
[0438] An outlet of the pump 1018 may be connected to an inlet of
the second (feed/recirculating) valve 1054 via pipe 1020a.
[0439] An outlet of the second (feed/recirculating) valve 1054 may
be connected to an inlet of a first manifold 1028 or a drip system
1034 via a pipe 10126a/1026b.
[0440] In an embodiment, the system 1000, 1100 may further comprise
a third (pump supply) valve 1055. The third (pump supply) valve
1055 may be any suitable switching valve. Suitable third (pump
supply) valves 1055 include, but are not limited to, ball valves.
For example, a suitable third (pump supply) valve 1055 is available
from GF Piping Systems. In an embodiment, the third (pump supply)
valve 1055 may be a GF Piping System Type 546 Electric Actuated
Ball Valve from GF Piping Systems. In an embodiment, the third
(pump supply) valve 1055 may be automatic or manual. In an
embodiment, the third (pump supply) valve 1055 may be electric or
pneumatic actuation. In an embodiment, the third (pump supply)
valve 1055 may be normally CLOSED.
[0441] In an embodiment, the third (pump supply) valve 1055 may
have 2-inch connections.
[0442] The third (pump supply) valve 1055 may be made of any
suitable corrosion-resistant material. The third (pump supply)
valve 1055 may be made of any suitable corrosion-resistant metals
or plastics. Suitable metals include, but are not limited to,
plastic-coated carbon steel, stainless steel, Hastelloy.RTM. alloy,
Monel.RTM. alloy and combinations thereof; and suitable plastic
include, but are not limited to, polyvinylchloride (PVC) polymers,
chlorinated polyvinyl chloride (CPVC) polymers, fiberglass
reinforced plastic (FRP), Kynar.RTM. polyvinylidene fluoride (PVDF)
polymers, polyethylene polymers, polypropylene polymers,
Teflon.RTM. perfluoroalkoxy (PFA) polymers, Teflon.RTM.
polytetrafluroethylene (PTFE) polymers, and combinations thereof.
In an embodiment, the third (pump supply) valve 1055 (wetted
components) may be made of polyvinyl chloride (PVC) and ethylene
propylene diene monomer (EPDM) rubber.
[0443] In an embodiment, the system 1000, 1100 may further comprise
an optional fifth limit switch (not shown) and an optional sixth
limit switch (not shown). (See e.g., FIGS. 1A-1B: 113 & 114).
In an embodiment, the fifth limit switch confirms that the third
(pump supply) valve 1055 is OPEN; and the sixth limit switch
confirms that the third (pump supply) valve 1055 is CLOSED.
[0444] The pump 1018 may be any suitable pump. Suitable pumps 1018
include, but are not limited to, centrifugal pumps. For example, a
suitable pump 1018 is available from MP Pumps Inc. In an
embodiment, the pump 1018 may be a FLOMAX.RTM. 8 Self-Priming
Centrifugal Pump from MP Pumps Inc. In an embodiment, the pump 1018
may be about 1 to about 3 HP centrifugal pump. In an embodiment,
the pump 1018 may be about a 1.5 HP variable speed pump.
[0445] In an embodiment, the pump 1018 may have 2-inch
connections.
[0446] The pump 1018 may be made of any suitable
corrosion-resistant material. The pump 1018 may be made of any
suitable corrosion-resistant metals or plastics. Suitable metals
include, but are not limited to, cast iron, stainless steel,
super-duplex stainless steel, AL-6XN alloy, Ni-Al-Brz alloy,
Hastelloy.RTM. alloy, Monel.RTM. alloy and combinations thereof and
suitable plastics include, but are not limited to, chlorinated
polyvinyl chloride (CPVC) polymers, fiberglass reinforced plastic
(FRP), Kynar.RTM. polyvinylidene fluoride (PVDF) polymers,
polyethylene polymers, polypropylene polymers, polyvinyl chloride
(PVC) polymers, Teflon.RTM. perfluoroalkoxy (PFA) polymers,
Teflon.RTM. polytetrafluroethylene (PTFE) polymers, and
combinations thereof. For example, the pump 1018 (wetted
components) may be made of stainless steel, super-duplex stainless
steel, AL-6XN alloy, Ni-Al-Brz alloy, Hastelloy.RTM. alloy,
Monel.RTM. alloy or FRD. In an embodiment, the pump 1018, including
internal wetted components, was made of 316 stainless steel. In an
embodiment, the pump 1018 may be made of cast iron if a shorter
service life is acceptable.
[0447] The pipe 1016a, 1016b, 1020a, 1026a, 1026b may be made of
any suitable corrosion-resistant pipe. The pipe 1016a, 1016b,
1020a, 1026a, 1026b may be any suitable corrosion-resistant metals
or plastics. Suitable metals include, but are not limited to,
plastic-coated carbon steel, stainless steel, super-duplex
stainless steel, AL-6XN alloy, Ni-Al-Brz alloy, Hastelloy.RTM.
alloy, Monel.RTM. alloy and combinations thereof; and suitable
plastics include, but are not limited to, chlorinated polyvinyl
chloride (CPVC) polymers, fiberglass reinforced plastic (FRP),
Kynar.RTM. polyvinylidene fluoride (PVDF) polymers, polyethylene
polymers, polypropylene polymers, polyvinyl chloride (PVC)
polymers, Teflon.RTM. perfluoroalkoxy (PFA) polymers, Teflon.RTM.
polytetrafluroethylene (PTFE) polymers, and combinations thereof.
In an embodiment, the pipe 1016a, 1016b, 1020a, 1026a, 1026b may be
made of plastic-coated carbon steel. In an embodiment, the pipe
1016a, 1016b, 1020a, 1026a, 1026b may be made of Plasite 7159
HAR-coated carbon steel. In an embodiment, the pipe 1008a, 1008b,
1016a, 1016b, 1020a, 1026a, 1026b may be made of 316 stainless
steel.
[0448] In an embodiment, the pipe 1016a, 1016b, 1020a, 1026a, 1026b
may be 2-inch pipe.
Flow Indicators or Meters
[0449] In an embodiment, the system 1000, 1100 may further comprise
a first flow indicator or meter 1022a and a second flow indicator
or meter 1022b.
[0450] An outlet of the first (feed) valve 1012 may be connected to
an inlet of the first flow indicator or meter 1022a via pipe
1008b.
[0451] An outlet of the first flow indicator or meter 1022a may be
connected to an inlet of a pipe 1016a or an inlet of a pump 1018
via a line 1008b.
[0452] An outlet of the second (feed/recirculating) valve 1054 may
be connected the inlet of the second flow indicator or meter 1022b
via a pipe 1026a.
[0453] An outlet of the second flow indicator or meter 1022b may be
fluidly connected to an inlet of a first manifold 1028 or a drip
system 1034 via a pipe 1026b.
[0454] The first flow indicator or meter 1022 and the second flow
indicator or meter 1022b may be any suitable flow indicator or
meter. Suitable first flow indicators or meters 1022a and a second
flow indicator or meter 1022b include, but are not limited to,
magnetic, paddlewheel, ultrasonic vortex and insertion-type vortex
flow meters. For example, a suitable first flow indicator or meter
1022a and a second flow indicator or meter 1022b is available from
Georg Fischer Signet LLC. In an embodiment, the first flow
indicator of meter 1022a and the second flow indicator or meter
1022b may be a Signet 2536 Rotor-X Paddlewheel Flow Sensor from
Georg Fischer Signet LLC. In an embodiment, the first flow
indicator of meter 1022a and the second flow indicator or meter
1022b may be electrically connected to the PLC or computing device
600.
[0455] The pipe 1008b, 1016a, 1026a, 1026b may be made of any
suitable corrosion-resistant pipe. The pipe 100b, 1016a, 1026a,
1026b may be any suitable corrosion-resistant metals or plastics.
Suitable metals include, but are not limited to, plastic-coated
carbon steel, stainless steel, super-duplex stainless steel, AL-6XN
alloy, Ni-Al-Brz alloy, Hastelloy.RTM. alloy, Monel.RTM. alloy and
combinations thereof; and suitable plastics include, but are not
limited to, chlorinated polyvinyl chloride (CPVC) polymers,
fiberglass reinforced plastic (FRP), Kynar.RTM. polyvinylidene
fluoride (PVDF) polymers, polyethylene polymers, polypropylene
polymers, polyvinyl chloride (PVC) polymers, Teflon.RTM.
perfluoroalkoxy (PFA) polymers, Teflon.RTM. polytetrafluroethylene
(PTFE) polymers, and combinations thereof. In an embodiment, the
pipe 1008b, 1016a, 1026a, 1026b may be made of plastic-coated
carbon steel. In an embodiment, the pipe 1008b, 1016a, 1026a, 1026b
may be made of Plasite 7159 HAR-coated carbon steel. In an
embodiment, the pipe 1008b, 1016a, 1026a, 1026b may be made of 316
stainless steel.
[0456] In an embodiment, the pipe 1008b, 1016a, 1026a, 1026b may be
2-inch pipe.
Optional Basket Strainer
[0457] In an embodiment, the system 1000, 1100 may further comprise
a basket strainer (not shown) and an optional first pressure sensor
(not shown). (See e.g., FIGS. 1A-1B: 124). An inlet of the basket
strainer (not shown) may be fluidly connected to an outlet of pipe
1026a and an outlet of the basket strainer (not shown) may be
fluidly connected to an inlet of pipe 1026a. The basket strainer
retains debris in the water feed to prevent clogging of the drip
orifice 1038. An obstruction in the basket strainer may be detected
via a decreased feed rate at the first flow indicator of meter
1022.
[0458] The basket strainer (not shown) may be any suitable basket
strainer, and may contain a reusable or disposable mesh or
synthetic fiber bag. (See e.g., FIGS. 1A-1B: 124). A suitable
basket strainer includes, but is not limited to, 1/8-inch
perforated baskets, contained within a simplex or duplex housing.
For example, a suitable basket strainer is available from Hayward
or Rosedale. In an embodiment, the basket strainer may be a
1/8-inch perforated basket from Hayward or Rosedale.
[0459] The basket strainer (not shown) may be made of any suitable
corrosion-resistant material. (See e.g., FIGS. 1A-1B: 124). The
basket strainer may be made of any suitable corrosion-resistant
metals or plastics. The basket strainer may be any suitable metal
or plastic basket strainer. Suitable metals include, but are not
limited to, stainless steel, Hastelloy.RTM. alloy, Monel.RTM. alloy
and combinations thereof; and suitable plastics include, but are
not limited to, chlorinated polyvinyl chloride (CPVC) polymers,
Kynar.RTM. polyvinylidene fluoride (PVDF) polymers, polyvinyl
chloride (PVC) polymers, Teflon.RTM. perfluoroalkoxy (PFA)
polymers, Teflon.RTM. polytetrafluroethylene (PTFE) polymers, and
combinations thereof. In an embodiment, the basket strainer
(basket) may be made of 316 stainless steel.
[0460] In an embodiment, the optional first pressure sensor (not
shown) may be fluidly connected to either the pipe 1026a or the
inlet of the basket strainer (not shown). (See e.g., FIGS. 1A-1B:
124). An obstruction in the basket strainer may also be detected
via an increase in pressure at the optional first pressure sensor
(not shown).
[0461] The optional first pressure sensor (not shown) may be any
suitable pressure sensor. For example, a suitable first pressure
sensor is available from Rosemount, Inc. In an embodiment, the
first pressure sensor may be a Rosemount 2088 Absolute and Gage
Pressure Transmitter from Rosemount, Inc.
[0462] An outlet of the pump 1018 may be connected to an inlet of a
basket strainer (not shown) via pipe 1020a/1026a. (See e.g., FIGS.
1A-1B: 124). An outlet of the basket strainer (not shown) may be
connected to an inlet of the drip system 1034 or the drip orifice
1038 via a pipe 1020b, 1026a, 1026b. (See e.g., FIGS. 1A-1B:
124).
[0463] The pipe 1020a, 1026a may be made of any suitable
corrosion-resistant pipe. The pipe 1020a, 1026a may be any suitable
metal or plastic pipe. Suitable metals include but are not limited
to, plastic-coated carbon steel, stainless steel, super-duplex
stainless steel, AL-6XN alloy, Ni-Al-Brz alloy, Hastelloy.RTM.
alloy, Monel.RTM. alloy and combinations thereof; and suitable
plastics include, but are not limited to, chlorinated polyvinyl
chloride (CPVC) polymers, fiberglass reinforced plastic (FRP),
Kynar.RTM. polyvinylidene fluoride (PVDF) polymers, polyethylene
polymers, polypropylene polymers, polyvinyl chloride (PVC)
polymers, Teflon.RTM. perfluoroalkoxy (PFA) polymers, Teflon.RTM.
polytetrafluroethylene (PTFE) polymers, and combinations thereof.
In an embodiment, the pipe 1020a, 1026a may be made of
plastic-coated carbon steel. In an embodiment, the pipe 1020a,
1026a may be made of Plasite 7159 HAR-coated carbon steel. In an
embodiment, the pipe 1020a, 1026a may be made of 316 stainless
steel.
[0464] In an embodiment, the pipe 1020a, 1026a may be 2-inch
pipe.
Drip System
[0465] In an embodiment, the system 1000, 1100 may further comprise
a first manifold 1028 and drip system 1034.
[0466] An outlet of the second (feed/recirculating) valve 1054 may
be connected to an inlet of the first manifold 1028, a drip system
1034 and/or a second (manifold) inlet to the container 1039 at a
second height of the container 1039 via a pipe 1020a/1026a/1026b.
In an embodiment, the second height of the container 1039 may be
about 8feet to about 12 feet (and any range or value there
between). In an embodiment, the second height of the container 1039
may be from about 9 to about 10 feet.
[0467] An outlet of the first manifold 1028 may be connected to the
inlet of a drip system 1034. In an embodiment, the drip system 1034
comprises a drip manifold 1036 and a drip orifice 1038, wherein the
drip orifice 1038 may be connected to or integral with an outlet of
the drip manifold 1036. In an embodiment, the drip system 1034 is
disposed inside the container 1039.
[0468] An outlet of the drip orifice 1038 discharges wastewater
and/or water droplets inside the container 1039. An upper portion
or top side of the container 1039 is enclosed with the demister
element 1045 to retain the wastewater and/or water droplets inside
the container 1039. In an embodiment, a side portion of the
container 1039 may also be enclosed with the demister element 1045
to retain the wastewater and/or water droplets inside the container
1039. The demister element 1045 is secured to and supported by the
container 1039 in a manner customary in the art.
[0469] At least some of the wastewater and/or water droplets
evaporate to form water vapor. The water vapor passes through the
demister element 1045 and out the evaporated water outlet 1046. Any
un-evaporated water is retained by the demister element 1045 and
falls to a sump (bottom) of the container 1039.
[0470] In an embodiment, the drip system 1034 comprises a drip
manifold 1036 and a plurality of drip orifice 1038', 1038'' wherein
each of the plurality of drip orifice 1038', 1038'' may be
connected to or integral with an outlet of the drip manifold 1036.
Outlets of the plurality of drip orifice 1038', 1038'' discharge
wastewater and/or water droplets inside the container 1039. An
upper portion or top side of the container 1039 is enclosed with
the plurality of demister elements 1045', 1045'' to retain the
wastewater and/or water droplets inside the container 1039. In an
embodiment, a side portion of the container 1039 is also enclosed
with the demister element 1045 to retain the wastewater and/or
water droplets inside the container 1039. The plurality of demister
elements 1045', 1045'' are secured to and supported by the
container 1039 in a manner customary in the art.
[0471] At least some of the wastewater and/or water droplets
evaporate to form water vapor. The water vapor passes through pores
(tortuous paths) in the plurality of demister elements 1045',
1045'' and out the evaporated water outlet 1046. Any un-evaporated
water is retained by the plurality of demister elements 1045',
1045'' and falls to the sump (bottom) of the container 1039.
[0472] The evaporated water outlet 1046 comprises a plurality of
outlet pores (not shown) in the plurality of demister elements
1045', 1045''.
[0473] The drip orifice 1038 may be any suitable drip orifice. In
an embodiment, the drip orifice 1038 are disposed inside the
container 1039.
[0474] The drip orifice 1038 may be made of any suitable
corrosion-resistant material. The drip orifice 1038 may be made of
any suitable corrosion-resistant metals or plastics. Suitable
metals, include, but are not limited to, brass, Cobalt Alloy 6,
reaction bonded silicon carbide (RB SC) ceramic, stainless steel,
Hastelloy.RTM. alloy, Monel.RTM. alloy, and combinations thereof;
and suitable plastics, include, but are not limited to,
polypropylene, polytetrafluroethylene (PTFE), polyvinyl chloride
(PVC), and combinations thereof. In an embodiment, the drip orifice
1038 (wetted component) may be made of PVC.
Mist Arresting System
[0475] In an embodiment, the system 1000, 1100 may further comprise
a mist arresting system 1044 and a container 1039. In an
embodiment, the mist arresting system 1044 comprises a plurality of
demister elements 1045', 1045'' and the container 1039.
Evaporation System
[0476] In an embodiment, the system 1000, 1100 may further comprise
an evaporation system 1058, 1064.
[0477] The performance of the evaporation system 1058, 1064 is
impacted significantly by two factors: an evaporation rate at which
water is evaporated (measured in barrels/day) and an emission rate
at which particulate contaminants are emitted (measured as a
tons/year). The evaporation rate is central to the function of the
evaporator system 1058, 1064. The more water evaporated for a given
amount of capital and energy input, the more value is created.
[0478] The emission rate is central to the ability to get a permit
for installation and operation of the system 1000, 1100. Wastewater
typically contains dissolved and suspended solids. Emissions of
these substances is regulated by both Federal and State agencies.
The ability to get a permit is based on the demonstrated
performance of the system's 1000, 1100 ability to limit the
emission of dissolved and suspended solids.
[0479] The system's 1000, 1100 technology represents a significant
improvement in both of these performance areas: evaporation rate
and emission rate.
[0480] In an embodiment, the system 1000, 1100 may further comprise
an evaporation system 1058, 1064 comprising a packing system 1058
and/or tray system 1064 (discussed below).
[0481] The system's 1000, 1100 use of the packing system 1058
and/or tray system 1064 (discussed below), the recirculation system
(discussed above) and an air blower and preheater system 1041
(discussed below) provides an improved evaporation performance when
compared to a plurality of spray nozzles 138, 23, 338, 442, 542 in
a large horizontal container 139, 239, 339, 444, 544 (discussed
above). This improved performance results from a more efficient
evaporation mechanism. The system 1000, 1100 uses a vertical
cascade of water passing through a porous packing 1062 to achieve
efficient transfer of water from the liquid phase to the vapor
phase. As a result, the system 1000, 1100 discharges evaporated
water (i.e., humidified air) through the evaporated water outlet
1046 in the demister element 1045 to ambient environment (i.e.,
air) at or near saturation at the air blower and preheater system's
1041 temperature and the system's 1000, 1100 pressure representing
a peak of process efficiency.
[0482] The vertical cascade of water and porous packing 1062 used
in the system 1000, 1100 provides additional benefits in terms of
particulate emissions. Particulate emissions may include both
dissolved solids (e.g., salts) and suspended solids (e.g., some
minerals). The vertical cascade of water reduces the formation of
dry particles and the porous packing 1062 shifts the evaporation
site from an airborne droplet to the surface of the porous packing
1062. A wide range of packing 1062 is available with different
sizes, shapes, and performance characteristics. The system's 1000,
1100 packing 1062 is selected to maximize evaporation and saturate
the airstream with water vapor while limiting contaminants in the
airstream.
Packing System and/or Tray System
[0483] In an embodiment, the system 1000, 1100 may further comprise
a packing system 1058 and/or tray system 1064.
[0484] In an embodiment, the packing system 1058 comprises a porous
tray 1060 installed at a third height in the container 1039 and a
packing 1062 from a third height of the container 1039 to a fourth
height in the container 1039. In an embodiment, the third height of
the container 1039 may be about 4 feet to about 8feet (and any
range or value there between). In an embodiment, the third height
of the container 1039 may be about 6 feet.
[0485] In an embodiment, the fourth height of the container 1039
may be about 5 feet to about 11 feet (and any range or value there
between). In an embodiment, the fourth height of the container 1039
may be about 9 feet.
[0486] The porous tray 1060 may be any suitable porous tray. For
example, a suitable porous tray 1060, includes but is not limited
to, a grating and a mesh. The porous tray 1060 may be made of any
suitable corrosion-resistant metals or plastics. Suitable metals
include, but are not limited to, stainless steel, Hastelloy.RTM.
alloy, Monel.RTM. alloy and combinations thereof; and suitable
plastics include, but are not limited to, chlorinated polyvinyl
chloride (CPVC) polymers, Kynar.RTM. polyvinylidene fluoride (PVDF)
polymers, polyvinyl chloride (PVC) polymers, polyethylene polymers,
polypropylene polymers, Teflon.RTM. perfluoroalkoxy (PFA) polymers,
Teflon.RTM. polytetrafluroethylene (PTFE) polymers, and
combinations thereof. In an embodiment, the porous tray 1060 may be
made of 316 stainless steel.
[0487] A wide range of packing 1062 is available with different
sizes, shapes, and performance characteristics. The packing 1062
provides a high surface area for interaction flowing water and
heated air with minimum flow restriction to maximize evaporation to
saturate the airstream with water vapor. The packing 1062 is
selected to maximize evaporation (i.e., saturate the airstream with
water vapor) while limiting contaminants in the airstream.
[0488] The packing 1062 may be any suitable packing. For example, a
suitable packing 1062, includes but is not limited to, random
packing, structured packing and combinations thereof.
[0489] The packing 1062 should be made of a material that is
relatively inert to the flowing water. The packing 1062 may be made
of any suitable ceramic material, corrosion-resistant metals,
plastics and combinations thereof. Suitable metals include, but are
not limited to, stainless steel, Hastelloy.RTM. alloy, Monel.RTM.
alloy and combinations thereof; and suitable plastics include, but
are not limited to, chlorinated polyvinyl chloride (CPVC) polymers,
Kynar.RTM. polyvinylidene fluoride (PVDF) polymers, polyvinyl
chloride (PVC) polymers, polyethylene polymers, polypropylene
polymers, Teflon.RTM. perfluoroalkoxy (PFA) polymers, Teflon.RTM.
polytetrafluroethylene (PTFE) polymers, and combinations
thereof.
[0490] In an embodiment, the packing 1062 may be made of ceramics,
corrosion-resistant metals, plastics, and combinations thereof. For
example, the packing 1062 may be made of ceramics and/or metals if
the air temperature exceeds the temperature limit for plastics.
[0491] In an embodiment, the packing 1062 may be made from
different materials (e.g., ceramics, plastics, stainless steel) to
improve performance at high temperatures.
[0492] In an embodiment, the packing 1062 may be a random packing.
In an embodiment, the packing 1062 may be a random packing made of
ceramics, corrosion-resistant metals, plastics, and combinations
thereof. In an embodiment, the packing 1062 may be made of a
Teflon.RTM. polytetrafluroethylene (PTFE) polymer random packing.
In an embodiment, the packing 1062 may be a Koch-Glitch
FLEXIRING.RTM. random packing.
[0493] In an embodiment, the packing 1062 may be a structured
packing. In an embodiment, the packing 1062 may be a structured
packing made of metals, plastics, and combinations thereof. In an
embodiment, the packing 1062 may be made of corrugated metals,
corrugated plastics, and combinations thereof. In an embodiment,
the packing 1062 may be made of mesh-type plastics, mesh-type
metals, and combinations thereof. In an embodiment, the packing
1062 may be made of solid-type plastics, solid-type metals, and
combinations thereof.
[0494] In an embodiment, the packing 1062 may be made from
different materials (e.g., ceramics, plastics, stainless steel) to
improve performance at high temperatures.
[0495] In an embodiment, the packing 1062 may be a loose fill
packing, a cartridge-type packing or another containerized form
packing. In an embodiment, the packing 1062 may be a cartridge-type
packing or another containerized form packing that is easily
removed for cleaning.
[0496] In an embodiment, the tray system 1064 comprises a first
cascading tray 1066 installed at a fifth height in the container
1039 and a second cascading tray 1068 installed at a sixth height
in the container 1039 and offset from the first cascading tray 1066
such that the wastewater and/or water droplets are transferred from
the first cascading tray 1066 to the second cascading tray 1068. In
an embodiment, the fifth height of the container 1039 may be about
5 feet to about 11 feet (and any range or value there between). In
an embodiment, the fifth height of the container 1039 may be about
9 feet.
[0497] In an embodiment, the sixth height of the container 1039 may
be about 4 feet to about 10 feet (and any range or value there
between). In an embodiment, the sixth height of the container 1039
may be from about 8feet to about 9 feet.
[0498] The first cascading tray 1066 and the second cascading tray
1068 may be any suitable cascading tray. For example, a suitable
first cascading tray 1066 and a second cascading tray 1068,
includes but is not limited to, an evaporation tray and a sieve
tray and combinations thereof. The first cascading tray 1066 and
the second cascading tray 1068 may be made of any suitable
corrosion-resistant metals or plastics. Suitable metals include,
but are not limited to, stainless steel, Hastelloy.RTM. alloy,
Monel.RTM. alloy and combinations thereof and suitable plastics
include, but are not limited to, chlorinated polyvinyl chloride
(CPVC) polymers, Kynar.RTM. polyvinylidene fluoride (PVDF)
polymers, polyvinyl chloride (PVC) polymers, polyethylene polymers,
polypropylene polymers, Teflon.RTM. perfluoroalkoxy (PFA) polymers,
Teflon.RTM. polytetrafluroethylene (PTFE) polymers, and
combinations thereof. In an embodiment, the first cascading tray
1066 and the second cascading tray 1068 may be made of 316
stainless steel.
[0499] In an embodiment, the system 1000, 1100 may further comprise
a first differential pressure switch 1053. The differential
pressure switch 1053 measures the pressure drop across the packing
system 1058 and/or tray system 1064. If the first differential
pressure switch 1053 is activated, the packing system 1058 and/or
tray system 1064 may be blocked due to flooding or scale build-up.
In an embodiment, the first differential pressure switch 148 may be
set to about 0.4 inches water column.
[0500] The differential pressure switch 1053 may be any suitable
differential pressure sensor. For example, a suitable differential
pressure switch 1053 is available from Dwyer Instruments Inc. In an
embodiment, the differential pressure switch 1053 may be a Series
3000 Photohelic Differential Pressure Gage from Dwyer Instruments
Inc. In an embodiment, the first differential pressure switch 1053
has a range from about 0 to about 0.5 inches water column.
[0501] The first differential pressure switch 1053 may be fluidly
connected to the container 1039.
Air Blower and Preheater System
[0502] In an embodiment, the system 1000, 1100 may further comprise
a first air blower 1042 and an optional second pressure sensor
1043c. In an embodiment, air flow from the first air blower 1042
disperses the wastewater and/or water droplets from the drip
orifice 1038. In an embodiment, the first air blower 1042 is
disposed through a wall of the container 1039 such that air flow
from the air blower 1042 is counter to and/or crossways to the
wastewater and/or water droplets from the drip orifice 1038. In an
embodiment, the first air blower 1042 may be disposed through a
wall of the container 1039 upstream of the demister elements 1045
as a forced-draft air blower. In other words, the container 1039
(i.e., evaporation chamber) may be operated at a positive pressure
via the forced-draft air blower 1042.
[0503] The first air blower 1042 may be any suitable axial blower.
In an embodiment, the first air blower 1042 may be a fixed or
variable-speed air blower. In an embodiment, the first air blower
1042 may provide from about 4,000 CFM to about 10,000 CFM (and any
range or value there between). In an embodiment, the first air
blower 1042 may provide about 4,500 CFM. In an embodiment, the
first air blower 1042 may be about 3 HP.
[0504] In an embodiment, the system 1000, 1100 may further comprise
an air blower and preheater system 1041. For example, the air
blower and preheater system 1041 may be disposed through a lower
wall of the container 1039 when the drip orifice 1038', 1038'' of
the drip system 1034 discharge toward the top of the container
1039.
[0505] In an embodiment, the air blower and heater system 1041
comprises a first air blower 1042 and an air preheater 1043. In an
embodiment, an air flow outlet of the first air blower 1042 is
fluidly connected to an air flow inlet of the air preheater
143.
[0506] The air preheater 1043 may be any suitable heater. For
example, a suitable heater includes, but is not limited to, a
direct-fired heater, a duct heater, a forced air heater, a line
heater, a recuperative heater, a supplied air heater, a tube-type
heater, and combinations thereof.
[0507] In an embodiment, the air preheater 1043 comprises a natural
gas burner. (See e.g., FIGS. 10A & 10B). The natural gas burner
may be any suitable burner. For example, suitable burners include,
but are not limited to, drying grain-type burners, firing
oiler-type burners, heating air-type burners, heating water-type
burners, and combinations thereof.
[0508] In an embodiment, the air preheater 1043 comprises a natural
gas burner and a natural gas flow control valve. The natural gas
flow control valve may be any suitable gas flow control valve. In
an embodiment, the natural gas flow control valve may provide a
fixed flow or a modulated flow to the natural gas burner to control
a resulting air temperature based on ambient air temperature and a
desired evaporation rate. In an embodiment, the natural gas flow
control valve may be modulated from a fully OPEN position to a
fully CLOSED position, and vice versa.
[0509] In an embodiment, the burner position may be moved relative
to position of the drip system 1034 and/or the packing system 1058
to optimize temperature distribution in the system 1000, 1100 to
increase efficiency and minimize particulate emissions.
[0510] In an embodiment, the preheater 1043 may also have a natural
gas powered electric generator. The natural gas powered electric
generator may be any suitable electric generator.
[0511] In an embodiment, the air preheater 1043 may provide an air
heating rate from about 0 million BTU per hour to about 5 million
BTU per hour (and any range or value there between). In an
embodiment, the air preheater 1043 may provide an air heating rate
of about 2.1 million BTU per hour.
[0512] In an embodiment, the air preheater 1043 may provide air
temperatures from about 50.degree. F. to about 400.degree. F.
[0513] In an embodiment, the optional second pressure sensor 1043c
may be fluidly connected to an air outlet of the air blower or the
air preheater 1043.
[0514] The optional second pressure sensor 1043c may be any
suitable pressure sensor. For example, a suitable second pressure
sensor 1043c is available from Rosemount, Inc. In an embodiment,
the optional second pressure sensor 1043c may be a Rosemount 2088
Absolute and Gage Pressure Transmitter from Rosemount, Inc.
Optional Second Air Inlet
[0515] The efficiency of the evaporation process may be increased
by mixing the hot air and wastewater to achieve a uniform
temperature in the airstream and, thereby, promoting complete
saturation of the air with water vapor. A turbulent airstream
promotes thorough mixing by increasing the physical contact of all
elements of the hot air with the counterflowing wastewater and/or
water droplets. One way of promoting turbulence is to have two or
more air inlets disposed through the wall of the container 1039 at
angle(s) such that the two or more airflows collide and mix
together. This mixing produces a single airstream of turbulent hot
air. Upon contact with the wastewater, this turbulent airstream is
maximally exposed to the wastewater and/or water droplets, and,
thereby, evaporation is maximized to produce a saturated
discharge.
[0516] Two or more air inlets may be achieved in several ways
including, but not limited to, ducting, two or more air blower and
preheater systems 1041, and combinations thereof. The use of two or
more air blower and preheater systems 1041 would have the
additional benefit of increasing the overall energy input to the
system 1000, 1100 and increasing the rate of evaporation, and,
thereby, increasing efficiency without significantly enlarging the
container 1039 (i.e., evaporation chamber).
Optional Second Air Blower
[0517] In an embodiment, the system 1000, 1100 may further comprise
a second air blower (not shown). In an embodiment, air flow from
the second air blower disperses the wastewater and/or water
droplets from the drip orifice 1038. In an embodiment, the second
air blower is disposed through a wall of the container 1039 such
that air flow from the air blower is counter to and/or crossways to
the wastewater and/or water droplets from the drip orifice 1038. In
an embodiment, the second air blower may be disposed through a wall
of the container 1039 downstream of the demister elements 1045 as
an induced-draft air blower. In an embodiment, the second air
blower is disposed through a wall of the container 1039 such that
the air flow from a second air blower is counter to and/or
crossways to the wastewater and/or water droplets from the drip
orifice 1038. In other words, the container 1039 (i.e., evaporation
chamber) may be operated at a negative pressure via the
induced-draft air blower.
[0518] The second air blower may be any suitable axial blower. In
an embodiment, the second air blower may be a fixed or
variable-speed air blower. In an embodiment, the second air blower
may provide from about 4,000 CFM to about 10,000 CFM (and any range
or value there between). In an embodiment, the second air blower
may provide about 4,500 CFM. In an embodiment, the second air
blower may be about 3 HP.
Optional Air Deflectors, Diffusers and Vanes
[0519] When the hot air from the air blower and preheater system
1041 is introduced into an air inlet of the container 1039 (i.e.,
evaporation chamber), turbulence may be created and, as result, the
efficiency of the evaporation process may be compromised. The
impact of turbulence can be reduced with a long or tall container
1039 but, to reduce the impact of uneven air distribution without
lengthening the container 1039, a deflector and/or a diffuser may
be installed within the container 1039 directly in the air flow
path to redirect the air to equalize low and high air pressure
areas and/or establish an even air discharge across the container
1039.
[0520] In an embodiment, the system 1000, 1100 may further comprise
a deflector and/or a diffuser, wherein the deflector and/or
diffuser may be disposed within the container 1039 at or near an
air inlet to the container 1039.
[0521] The deflector and/or diffuser may be any suitable deflector
or diffuser capable of redirecting the air to equalize low and high
air pressure areas and/or to establish an even air discharge across
the container 1039. For example, a suitable deflector or diffuser
includes, but is not limited to, a flat metal sheet, an inclined
metal sheet, a perforated metal sheet, a solid metal sheet, and
combinations thereof to create a turning vane effect.
[0522] The deflector and/or diffuser may be any suitable size and
shape.
[0523] In an embodiment, the size and location of the deflector
and/or diffuser may be adjusted to achieve optimal performance
based on air temperature, altitude, humidity, and other
factors.
[0524] In an embodiment, the deflector and/or diffuser may be
mounted to the container 1039 to allow adjustments during operation
to achieve optimal performance based on air temperature, altitude,
humidity, and other factors.
[0525] In an embodiment, the system 1000, 1100 may further comprise
a vane, wherein the vane may be disposed in the container 1039 at
or near an air inlet to the container 1039.
[0526] The vane may be any suitable vane capable of turning the
direction of the air flow about 90 degrees (e.g., from horizontal
to vertical) in the container 1039. For example, a suitable vane
includes, but is not limited to, a flat metal sheet, an inclined
metal sheet, a perforated metal sheet, a solid metal sheet, and
combinations thereof to create a turning vane effect.
[0527] The vane may be any suitable size and shape.
[0528] In an embodiment, the size and location of the vane may be
adjusted to achieve optimal performance based on air temperature,
altitude, humidity, and other factors. In an embodiment, the vane
may extend across the cross-section (e.g., diameter) of the
container 1039.
[0529] In an embodiment, the system 1000, 1100 may further comprise
a vane, wherein the vane may be disposed in an air duct between an
air discharge outlet of the air blower and preheat system 1041 and
an air inlet to the container 1039.
[0530] The vane may be any suitable vane capable of achieving the
desired degree of mixing in the air duct. For example, a suitable
vane includes, but is not limited to, a flat metal sheet, an
inclined metal sheet, a perforated metal sheet, a solid metal
sheet, and combinations thereof to create a mixing vane effect.
[0531] The vane may be any suitable size and shape.
[0532] In an embodiment, the size and location of the vane may be
adjusted to achieve optimal performance based on air temperature,
altitude, humidity, and other factors.
[0533] The air duct may be any suitable size and shape. In an
embodiment, the length of the air duct may be adjusted to achieve
optimal performance.
Optional Insulation and Supplementary Heating
[0534] In an embodiment, the system 1000, 1100 may further comprise
supplementary heating using waste heat from a natural gas electric
generator or a natural gas burner to protect the system 1000, 1100
from subfreezing temperatures.
[0535] As discussed above, the system 1000, 1100 may have an air
preheater 1043 having a natural gas burner to preheat ambient air
and to accelerate water evaporation process. In some embodiments,
the air preheater 1043 may also have a natural gas-powered electric
generator. The air preheater 1043 may generate waste heat that may
be used to heat the system's 1000, 1100 components (e.g., pipes,
pumps, valves, etc.) to protect the system 1000, 1100 from
subfreezing temperatures.
[0536] The system 1000, 1100 may operate continuously (i.e., 24
hours per day, 356 days per year) in remote locations with cold
weather conditions (e.g., down to about 10.degree. F.). For
example, ambient temperatures may be below freezing (e.g., from
about 10.degree. F. to about 32.degree. F.) for extended periods of
time. If these subfreezing temperatures continue for days, weeks or
even months, the water in an unprotected system 1000, 1100 is
subject to freezing. If the water freezes, the unprotected system
1000, 1100, namely, pumps and valves would likely cease to function
due to freezing damage, requiring operator intervention and costly
repairs of the damaged system 1000, 1100.
[0537] The system 1000, 1100 should be capable of operating in cold
weather conditions to sustain evaporation operations in nearly all
weather conditions. Cold weather shutdowns not only reduce the
efficiency of the evaporation process, they also require operator
intervention to restart the system 1000, 1100 because frozen
components must be thawed, checked for damage, and, if necessary,
repaired or replaced before restarting. Further, cold weather
conditions in some locations may last for weeks or months making
subfreezing operational reliability essential to operational
effectiveness.
[0538] In an embodiment, the system 1000, 1100 may further comprise
one or more of insulation, heat-tracing (i.e., resistance heating)
and supplementary heating to protect the system 1000, 1100 from
subfreezing temperatures. For example, the one or more of
insulation, heat-tracing and supplementary heating for the system
1000, 1100 includes, but is not limited to, the following: [0539]
insulation of weatherproof enclosures [0540] insulation of
components (e.g., pipes, pumps, valves, etc.) [0541] supplementary
heating (e.g., direct heating, heat-tracing, using waste heat from
a generator or a burner).
[0542] In an embodiment, the system 1000, 1100 may further comprise
insulation, wherein the insulation is disposed around the system's
1000, 1100 components (e.g., pipes, pumps, valves, etc.). In an
embodiment, the system 1000, 1100 may further comprise an enclosure
(for one or more of pumps and valves) and insulation, wherein the
insulation is disposed around the system's 1000, 1100 components
(e.g., pipes, pumps, valves, etc.) and/or inside the enclosure.
Insulation offers short term protection from low temperature
conditions, but supplementary heating is required to function
reliably at prolonged low temperatures.
[0543] In an embodiment, the system 1000, 1100 may further comprise
heat tracing, wherein the heat tracing is disposed around the
system's 1000, 1100 components (e.g., pipes, pumps, valves, etc.).
Heat tracing provides long term protection from low temperature
conditions, but it consumes too much electrical power to be
efficient and it cannot generate heat in an event of electrical
power outage.
[0544] In an embodiment, the system 1000, 1100 may further comprise
supplementary heating using direct heating and/or using waste heat
from a burner or a generator to protect the system's 1000, 1100
components (e.g., pipes, pumps, valves, etc.) from subfreezing
temperatures. For example, the supplementary heating using direct
heating and/or using waste heat from a burner or a generator
includes, but is not limited to, the following: [0545] direction of
waste heat from the burner into an enclosure via passive radiation
[0546] direction of waste heat from the generator into the
enclosure via a metal duct. [0547] installation of a natural gas
powered infrared heater in the enclosure
[0548] In an embodiment, the system 1000, 1100 may further comprise
an enclosure (for one or more of pumps and valves), and a direct
heater (e.g., a natural gas powered infrared heater), wherein the
direct heater is disposed inside the enclosure.
[0549] In an embodiment, the system 1000, 1100 may further comprise
a burner and an enclosure (for one or more of pumps and valves),
wherein waste heat is directed into the enclosure via passive
radiation.
[0550] In an embodiment, the system 1000, 1100 may further comprise
a duct, an enclosure (for one or more of pumps and valves), and a
generator, wherein waste heat from the generator is directed into
the enclosure via the duct.
Optional Air, Argon or Nitrogen Purge System
[0551] In an event of an electrical power outage and/or a loss of
natural gas pressure, the system 1000, 1100 would no longer be able
to generate supplementary heat. The loss electrical power outage
would also deprive the system 1000, 1100 of an ability to purge the
system's components (e.g., pipes, pumps, valves, etc.) using the
electrical pumps.
[0552] To provide extra freeze protection during an electrical
power outage and/or a loss of natural gas pressure, the system
1000, 1100 may further comprise an air, argon or nitrogen purge
system 10008 that can "blow out" water from the system's components
(e.g., pipes, pumps, valves, etc.) for freeze protection of the
system. In an embodiment, the air, argon or nitrogen purge system
10008 of the system 1000, 1100 may be activated by an ambient
temperature sensor powered by a battery-driven emergency power
system. Further, the capacity of the air, argon or nitrogen purge
system 10008 may be adjusted to "blow out" water from the system's
components (e.g., pipes, pumps, valves, etc.) as well as the feed
and discharge pipelines that connect the system 1000, 1100 to the
wastewater source or tank farm.
[0553] In an embodiment, the system 1000, 1100 may further comprise
an air, argon or nitrogen purge system 10008 comprising an air,
argon or nitrogen source 10010, a fifth (air, argon or nitrogen)
valve 10012 and an optional air, argon or nitrogen shut-off valve
10014 for freeze protection of the system.
[0554] An outlet of the air, argon or nitrogen source 10010 may be
connected to an inlet of the fifth (air, argon or nitrogen) valve
10012 via a pipe 10016a.
[0555] An outlet of the fifth (air, argon or nitrogen) valve 10012
may be connected to an inlet of the optional fifth (air, argon or
nitrogen) shut-off valve 10014 or an inlet to the pipe 1008b via a
pipe 10016b.
[0556] An outlet of the optional fifth (air, argon or nitrogen)
shut-off valve 10014 may be connected to an inlet to the pipe 1008b
via a pipe 10016c.
[0557] The air, argon or nitrogen source 10010 may be any suitable
air, argon or nitrogen source. For example, a suitable air, argon
or nitrogen source 10010 includes, but is not limited to, an air
compressor, a high pressure air cylinder, a high pressure argon
cylinder and a high pressure nitrogen cylinder.
[0558] In an embodiment, the air, argon or nitrogen may be any
suitable purge pressure. For example a suitable purge pressure
includes, but is not limited to, about 15-20 psig.
[0559] In an embodiment, the system 1000, 1100 may further comprise
a fifth (air, argon or nitrogen) valve 10012. The fifth (air, argon
or nitrogen) valve 10012 may be any suitable switching valve.
Suitable fifth (air, argon or nitrogen) valves 10012 include, but
are not limited to, ball valves. For example, a suitable fifth
(air, argon or nitrogen) valve 10012 is available from GF Piping
Systems. In an embodiment, the fifth (air, argon or nitrogen) valve
10012 may be a GF Piping Systems Type 546 Electric Actuated Ball
Valve from GF Piping Systems. In an embodiment, the fifth (air,
argon or nitrogen) valve 10012 may be automatic or manual. In an
embodiment, the fifth (air, argon or nitrogen) valve 10012 may be
electric or pneumatic actuation. In an embodiment, the fifth (air,
argon or nitrogen) valve 10012 may be normally CLOSED. In an
embodiment, the fifth (air, argon or nitrogen) valve 10012 may be
normally OPEN.
[0560] In an embodiment, the fifth (air, argon or nitrogen) valve
10012 may have 1/4-inch connections.
[0561] In an embodiment, the system 1000, 1100 may further comprise
a fifth (air, argon or nitrogen) shut-off valve 10014. The fifth
(air, argon or nitrogen) shut-off valve 10014 may be any suitable
shut-off valve. Suitable fifth (air, argon or nitrogen) shut-off
valves 10014 include, but are not limited to, ball valves and
butterfly valves. For example, a suitable fifth (air, argon or
nitrogen) shut-off valve 10014 is available from GF Piping Systems.
In an embodiment, the fifth (air, argon or nitrogen) shut-off valve
10014 may be a GF Piping Systems Type 546 Ball Valve from GF Piping
Systems. In an embodiment, the fifth (air, argon or nitrogen)
shut-off valve 10014 may be automatic or manual. In an embodiment,
the fifth (air, argon or nitrogen) shut-off valve 10014 may be
normally CLOSED. In an embodiment, the fifth (air, argon or
nitrogen) shut-off valve 10014 may be normally OPEN.
[0562] In an embodiment, the fifth (air, argon or nitrogen)
shut-off valve 10014 may have 1/4-inch connections.
[0563] The pipe 10016a, 10016b, 10016c may be made of any suitable
corrosion-resistant pipe. The pipe 10016a, 10016b, 10016c may be
made of any suitable corrosion-resistant metals or plastics.
Suitable metals include, but are not limited to, brass, copper,
stainless steel and combinations thereof; and suitable plastics
include, but are not limited to, chlorinated polyvinyl chloride
(CPVC) polymers, fiberglass reinforced plastic (FRP), Kynar.RTM.
polyvinylidene fluoride (PVDF) polymers, polyethylene polymers,
polypropylene polymers, polyvinyl chloride (PVC) polymers,
Teflon.RTM. perfluoroalkoxy (PFA) polymers, Teflon.RTM.
polytetrafluroethylene (PTFE) polymers, and combinations thereof.
In an embodiment, the pipe 10016a, 10016b, 10016c may be made of
316 stainless steel.
[0564] In an embodiment, the pipe 10016a, 10016b, 10016c may be
1/4-inch pipe.
Optional Level Column
[0565] In an embodiment, the system 1000, 1100 may further comprise
a level column 10000, a third shut-off valve 10003 and a fourth
shut-off valve 10004.
[0566] A lower end of the level column 10000 may be fluidly
connected to an inlet of the forth shut-off valve 10004 via pipe
10002a and to an inlet of the third shut-off valve 10003 via pipe
10006b. An outlet of the third shut-off valve 10003 is fluidly
connected to a fourth inlet of the container 1039 at a seventh
height of the container 1039 via pipe 10006c. In an embodiment, the
seventh height of the container 1039 may be about four inches to
about 1 foot (and any range or value there between). In an
embodiment, the seventh height of the container 1039 may be about 6
inches.
[0567] The level column 10000 may be any suitable level column.
Suitable level columns 10000, include but are not limited to,
column level indicators.
[0568] The pipe 10006a, 10006b, 10006c may be made of any suitable
corrosion-resistant pipe. The pipe 10006a, 10006b, 10006c may be
any suitable corrosion-resistant metals or plastics. Suitable
metals include, but are not limited to, plastic-coated carbon
steel, stainless steel, super-duplex stainless steel, AL-6XN alloy,
Ni-Al-Brz alloy, Hastelloy.RTM. alloy, Monel.RTM. alloy and
combinations thereof; and suitable plastics include, but are not
limited to, chlorinated polyvinyl chloride (CPVC) polymers,
fiberglass reinforced plastic (FRP), Kynar.RTM. polyvinylidene
fluoride (PVDF) polymers, polyethylene polymers, polypropylene
polymers, polyvinyl chloride (PVC) polymers, Teflon.RTM.
perfluoroalkoxy (PFA) polymers, Teflon.RTM. polytetrafluroethylene
(PTFE) polymers, and combinations thereof. In an embodiment, the
pipe 10006a, 10006b, 10006c may be made of plastic-coated carbon
steel. In an embodiment, the pipe 10006a, 10006b, 10006c may be
made of Plasite 7159 HAR-coated carbon steel. In an embodiment, the
pipe 10006a, 10006b, 10006c may be made of 316 stainless steel.
[0569] In an embodiment, the pipe 10006a, 10006b, 10006c may be
2-inch pipe.
Discharge System
[0570] In an embodiment, the system 1000, 1100 may further comprise
a check valve 1063, a fourth (discharge) valve 1069 and a second
(discharge) shut-off valve 1074. An outlet of a pipe 1020a may be
connected to an inlet of the fourth (discharge) valve 1069 via a
pipe 1020b; and an outlet of the fourth (discharge) valve 1069 may
be connected to an inlet of the check valve 1063 or an inlet of the
second (discharge) shut-off valve 1074 via a pipe 1072.
[0571] An outlet of the check valve 1063 or an outlet of the second
(discharge) shut-off valve 1074 may be connected to an inlet of the
second (discharge) flange 1076 via a pipe 1075.
[0572] In an embodiment, the system 1000, 1100 may further comprise
a fourth (discharge) valve 1069. The fourth (discharge) valve 1069
may be any suitable switching valve. Suitable fourth (discharge)
valves 1069 include, but are not limited to, ball valves. For
example, a suitable fourth (discharge) valve 1069 is available from
GF Piping Systems. In an embodiment, the fourth (discharge) valve
1069 may be a GF Piping Systems Type 546 Electric Actuated Ball
Valve from GF Piping Systems. In an embodiment, the fourth
(discharge) valve 1069 may be automatic or manual. In an
embodiment, the fourth (discharge) valve 1069 may be electric or
pneumatic actuation. In an embodiment, the fourth (discharge) valve
1069 may be normally CLOSED.
[0573] In an embodiment, the fourth (discharge) valve 1069 may have
2-inch connections.
[0574] In an embodiment, the system 1000, 1100 may further comprise
a second (discharge) shut-off valve 1074. The second (discharge)
shut-off valve 1074 may be any suitable shut-off valve. Suitable
second (discharge) shut-off valves 1074 include, but are not
limited to, ball valves and butterfly valves. For example, a
suitable second (discharge) shut-off valve 1074 is available from
GF Piping Systems. In an embodiment, the second (discharge)
shut-off valve 1074 may be a GF Piping Systems Type 546 Ball Valve
from GF Piping Systems. In an embodiment, the second (discharge)
shut-off valve 1074 may be automatic or manual. In an embodiment,
the second (discharge) shut-off valve 1074 may be normally
CLOSED.
[0575] In an embodiment, the second (discharge) shut-off valve 1074
may have 2-inch connections.
[0576] The fourth (discharge) valve 1069 and the second (discharge)
shut-off valve 1074 may be made of any suitable corrosion-resistant
material. The fourth (discharge) valve 1069 and the second
(discharge) shut-off valve 1074 may be made of any suitable
corrosion-resistant metals or plastics. Suitable metals include,
but are not limited to, plastic-coated carbon steel, stainless
steel, Hastelloy.RTM. alloy, Monel.RTM. alloy and combinations
thereof; and suitable plastic include, but are not limited to,
polyvinylchloride (PVC) polymers, chlorinated polyvinyl chloride
(CPVC) polymers, fiberglass reinforced plastic (FRP), Kynar.RTM.
polyvinylidene fluoride (PVDF) polymers, polyethylene polymers,
polypropylene polymers, Teflon.RTM. perfluoroalkoxy (PFA) polymers,
Teflon.RTM. polytetrafluroethylene (PTFE) polymers, and
combinations thereof. In an embodiment, the fourth (discharge)
valve 1069 and the second (discharge) shut-off valve 1074 (wetted
components) may be made of polyvinyl chloride (PVC) and ethylene
propylene diene monomer (EPDM) rubber.
[0577] In an embodiment, the system 1000, 1100 may further comprise
a check valve 1063. The check valve 1063 may be any suitable check
valve. Suitable check valves 1063 include, but are not limited to,
one-way valves. An outlet of the fourth (discharge) valve 1069 may
be connected to an inlet of a check valve 1063; and an outlet of
the check valve 1063 may be connected to an inlet of a second
(discharge) shut-off valve 1074.
[0578] In an embodiment, the system 1000, 1100 may further comprise
a seventh limit switch (not shown) and an eighth limit switch (not
shown). (See e.g., FIGS. 1A-1B: 113 & 114). In an embodiment,
the seventh limit switch (not shown) confirms that the fourth
(discharge) valve 1069 is OPEN; and the eighth limit switch (not
shown) confirms that the fourth (discharge) valve 1069 is
CLOSED.
[0579] The pipe 1072, 1075 may be made of any suitable
corrosion-resistant pipe. The pipe 1072, 1075 may be made of any
suitable corrosion-resistant metals or plastics. Suitable metals
include, but are not limited to, plastic-coated carbon steel,
stainless steel, super-duplex stainless steel, AL-6XN alloy,
Ni-Al-Brz alloy, Hastelloy.RTM. alloy, Monel.RTM. alloy and
combinations thereof; and suitable plastics include, but are not
limited to, chlorinated polyvinyl chloride (CPVC) polymers,
fiberglass reinforced plastic (FRP), Kynar.RTM. polyvinylidene
fluoride (PVDF) polymers, polyethylene polymers, polypropylene
polymers, polyvinyl chloride (PVC) polymers, Teflon.RTM.
perfluoroalkoxy (PFA) polymers, Teflon.RTM. polytetrafluroethylene
(PTFE) polymers, and combinations thereof. In an embodiment, the
pipe 1072, 1075 may be made of plastic-coated carbon steel. In an
embodiment, the pipe 1072, 1075 may be made of Plasite 7159
HAR-coated carbon steel. In an embodiment, the pipe 1072, 1075 may
be made of 316 stainless steel.
[0580] In an embodiment, the pipe 1072, 1075 may be 2-inch
pipe.
Optional Sensors and Meters
[0581] In an embodiment, the system 1000, 1100 may further comprise
a first temperature sensor (not shown), a second temperature sensor
1043a, a third temperature sensor 1043b, a first conductivity meter
(not shown), an optional second conductivity meter (not shown),
and/or a third flow indicator or meter 1073. (See e.g., FIGS.
1A-1B: 130, 131, 132 & 173).
[0582] The first temperature sensor (not shown) may be fluidly
connected to the first manifold 1028.
[0583] The second temperature sensor 1043a may be fluidly connected
to an air outlet of the air preheater 1043.
[0584] The third temperature sensor 1043b may be fluidly connected
to a headspace in the container 1039 above the drip system 1034 and
adjacent to the demister element 1045.
[0585] The first temperature sensor (not shown) may be any suitable
temperature measuring device. (See e.g., FIGS. 1A-1B: 130). For
example, a suitable first temperature sensor is available from
Ashcroft Inc. In an embodiment, the first temperature sensor may be
a Bi-Metallic Dial Thermometer from Ashcroft Inc. In an embodiment,
the first temperature sensor may be electrical or manual.
[0586] The second temperature sensor 1043a and the third
temperature sensor 1043b may be any suitable temperature measuring
device. For example, a suitable second temperature sensor 1043a and
a third temperature sensor 1043b is available from Pyromation Inc.
In an embodiment, the second temperature sensor 1043a and the third
temperature sensor 1043b may be a Resistant Temperature Detector
(RTD) temperature sensor from Pyromation Inc. In an embodiment, the
second temperature sensor 1043a and the third temperature sensor
1043b may be electrical or manual.
[0587] The first conductivity meter (not shown) may be fluidly
connected to the first manifold 1028; and the optional second
conductivity meter (not shown) may be fluidly connected to the
first manifold 1028. (See e.g., FIGS. 1A-1B: 131 & 132).
[0588] The first conductivity meter (not shown) monitors the
conductivity of the inlet (feed) and/or condensed (recycled)
wastewater from the external wastewater source. (See e.g., FIGS.
1A-1B: 131). If the first conductivity meter measures a
predetermined minimum conductivity (e.g., indicating presence of
oil in feed water), the system 1000 is shut off.
[0589] The first conductivity meter (not shown) may be any suitable
conductivity meter. (See e.g., FIGS. 1A-1B: 131). For example, a
suitable first conductivity meter is available from Cole-Parmer
Instrument Company. In an embodiment, the first conductivity meter
may be a Model ML-19504-04 Toroidal Conductivity Sensor from
Cole-Parmer Instrument Company. In an embodiment, the first
conductivity sensor may be electrically connected to the PLC or
computing device 600. In an embodiment, the first conductivity
sensor may have a range from about 0 .mu.S/cm to about 1,000,000
.mu.S/cm (and any range or value there between).
[0590] The optional second conductivity meter (not shown) monitors
the conductivity of the inlet (feed) or condensed (recycle)
wastewater from the external wastewater source. If the second
conductivity meter indicates the condensed wastewater (brine) has
reached a predetermined maximum conductivity, the third (discharge)
shut-off valve 1074 is switched to the OPEN position.
[0591] The optional second conductivity meter (not shown) may be
any suitable conductivity meter. For example, a suitable first
conductivity meter (not shown) is available from Cole-Parmer
Instrument Company. In an embodiment, the first conductivity meter
(not shown) may be a Model ML-19504-04 Toroidal Conductivity Sensor
electrically connected to a Model ML-94785-12 Process Meter from
Cole-Parmer Instrument Company. In an embodiment, the second
conductivity sensor (not shown) may be electrically connected to
the PLC or computing device 600. In an embodiment, the second
conductivity sensor (not shown) may have a range from about 0
.mu.S/cm to about 1,000,000 .mu.S/cm (and any range or value there
between).
[0592] The third flow indicator or meter 1073 may be fluidly
connected to pipe 1072. The third flow indicator or meter 1073
monitors the flow rate of the discharge to the discharge outlet
1076.
[0593] The third flow indicator or meter 1073 may be any suitable
flow indicator or meter. Suitable third flow indicators or meters
1073 include, but are not limited to, magnetic, paddlewheel,
ultrasonic vortex and insertion-type vortex flow meters. For
example, a suitable third flow indicator or meter 1073 is available
from Georg Fischer Signet LLC. In an embodiment, the third flow
indicator or meter 1073 may be a Signet 2536 Rotor-X Paddlewheel
Flow Sensor from Georg Fischer Signet LLC. In an embodiment, the
third flow indicator or meter 1073 may be electrically connected to
the PLC or computing device 600.
Optional Limit/Level, Pressure and Temperature Switches
[0594] In an embodiment, the system 1000, 1100 may further comprise
a first pressure switch (not shown), an air temperature sensor (not
shown), a second high differential pressure switch (not shown), a
third high, high differential pressure switch (not shown), a first
high, high limit switch 1049, a low limit switch (not shown), a
high limit switch (not shown), a second high, high limit switch
(not shown), and a second pressure switch (not shown). (See e.g.,
FIGS. 1A-1B: 110, 140, 147, 148, 149, 150, 151, 152 & 159).
[0595] The first pressure switch (not shown) monitors pressure of
inlet wastewater to the pump 1018. (See e.g., FIGS. 1A-1B: 110).
The first pressure switch may be any suitable pressure switch. For
example, a suitable first pressure switch is available from
AutomationDirect.com Inc. In an embodiment, the first pressure
switch may be a ProSense.RTM. MPS25 Series Mechanical Pressure
Switch from AutomationDirect.com Inc.
[0596] The first pressure switch (not shown) may be fluidly
connected to the pipe 1008. (See e.g., FIGS. 1A-1B: 110).
[0597] The second high differential pressure switch (not shown)
monitors the air pressure in the container 1039. (See e.g., FIGS.
1A-1B: 147). If the second high differential pressure switch is
activated, the first air blower 1042 and/or the second air blower
is operating. In an embodiment, the second high differential
pressure switch may be set to +/-0.15 inches water column.
[0598] The second high differential pressure switch (not shown) may
be any suitable differential pressure sensor. (See e.g., FIGS.
1A-1B: 147). For example, a suitable second high differential
pressure switch is available from Dwyer Instruments Inc. In an
embodiment, the second high differential pressure switch may be a
Series 3000 Photohelic Differential Pressure Gage from Dwyer
Instruments Inc. In an embodiment, the second high differential
pressure switch has a range from about 0 to about 0.5 inches water
column.
[0599] The second high differential pressure switch (not shown) may
be fluidly connected to the container 1039. (See e.g., FIGS. 1A-1B:
147).
[0600] The third high, high differential pressure switch (not
shown) also monitors air pressure in the container. (See e.g.,
FIGS. 1A-1B: 148). If the third high, high differential pressure
switch is activated, the mist arresting system 1044 may be blocked
due to flooding or scale build-up. In an embodiment, the third
high, high differential pressure switch may be set to about +/-0.40
inches water column.
[0601] The third high, high differential pressure switch (not
shown) may be any suitable differential pressure sensor. (See e.g.,
FIGS. 1A-1B: 148). For example, a suitable third high, high
differential pressure switch is available from Dwyer Instruments
Inc. In an embodiment, the third high, high differential pressure
switch may be a Series 3000MR Photohelic Differential Pressure Gage
from Dwyer Instruments Inc. In an embodiment, the third high, high
differential pressure switch may have a range from about 0 to about
0.5 inches water column.
[0602] The third high, high differential pressure switch (not
shown) may be fluidly connected to the container 1039. (See e.g.,
FIGS. 1A-1B: 148).
[0603] The first high, high limit switch (not shown), low limit
switch (not shown) and high limit switch (not shown) monitor
various water levels in the sump (bottom) of the container 1039.
(See e.g., FIGS. 1A-1B: 149, 150 & 151). The second high, high
limit switch (not shown) monitors water levels in a secondary
containment. (See e.g., FIGS. 1A-1B: 152).
[0604] The high, high limit switches 1049, low limit switch (not
shown), and high limit switch (not shown) may be any suitable water
level switches. (See e.g., FIGS. 1A-1B: 149, 150, 151 & 152).
Suitable water level switches include, but are not limited to,
capacitive proximity, float, magnetic and vibrating fork. For
example, the high, high limit switches 1049, low limit switch, and
high limit switch are available from AutomationDirect.com Inc. In
an embodiment, the high, high limit switches 1049, low limit
switch, and high limit switch may be TU Series Model M18 Round
Inductive Proximity Sensors from AutomationDirect.com Inc.
[0605] The first high, high limit switch 1049, low limit switch
(not shown), and high limit switch (not shown) may be fluidly
connected near the sump (bottom) of the container 1039. (See e.g.,
FIGS. 1A-1B: 149, 150, 151).
[0606] The second high, high limit switch (not shown) may be
fluidly connected outside the container 1039 for monitoring water
levels in the secondary containment. (See e.g., FIGS. 1A-1B:
152)
First Optional Acid Conditioning System
[0607] In an embodiment, the system 1000, 1100 may further comprise
an optional acid conditioning system (not shown). (See e.g., FIGS.
1A-1B: 177). The acid conditioning system (not shown) comprises an
acid tote (not shown) and an acid metering pump (not shown). (See
e.g., FIGS. 1A-1B: 177, 178 & 180).
[0608] The acid may be any suitable acid. Suitable acids include,
but are not limited to, hydrochloric acid and sulfuric acid. In an
embodiment, the acid may be hydrochloric acid (20 baume). In an
embodiment, the acid may be sulfuric acid (98%). In an embodiment,
the desired pH of the wastewater is about 6.5 or below to minimize
calcium carbonate scaling. In an embodiment, the desired pH of the
wastewater may be above 6.5 if a scale inhibitor is added to
minimize carbonate and non-carbonate scaling. In an embodiment, the
amount of acid solution added varies, depending on inlet water
conditions (e.g., pH, alkalinity).
[0609] In an embodiment, the desired pH of the wastewater may be
above 6.5 if a scale inhibitor is added to minimize carbonate and
non-carbonate scaling.
[0610] An outlet of the acid tote (not shown) may be fluidly
connected to an inlet of the acid metering pump (not shown) via
tubing (not shown); and an outlet of the acid metering pump (not
shown) is fluidly connected to the container 1039 or to the pipe
1008 via tubing (not shown). (See e.g., FIGS. 1A-1B: 178, 179, 180
& 181).
[0611] The acid tote (not shown) may be any suitable acid tote or
other bulk chemical storage unit. (See e.g., FIGS. 1A-1B: 178).
Suitable acid totes include, but are not limited to, an industry
standard shipping tote. For example, a suitable acid tote is
available from National Tank Outlet. In an embodiment, the acid
tote may be a 275 gallon or a 330 gallon industry standard shipping
tote. In an embodiment, the acid tote may be a 55 gallon drum.
[0612] The acid metering pump (not shown) may be any suitable acid
metering pump. (See e.g., FIGS. 1A-1B: 180). Suitable acid metering
pumps include, but are not limited to, electronic diaphragm,
peristaltic and positive displacement pumps. For example, a
suitable acid metering pump is available from Anko Products, Inc.
In an embodiment, the acid metering pump may be a self-priming
peristaltic pump from Anko Products, Inc. In an embodiment, the
acid metering pump may be a Mityflex Model 907 self-priming
peristaltic pump from Anko Products, Inc.
[0613] The tubing (not shown) may be made of any suitable
corrosion-resistant tubing. (See e.g., FIGS. 1A-1B: 179 & 181).
The tubing may be made of any suitable corrosion-resistant metals
or plastics. Suitable metals include but are not limited to, AL-6XN
alloy, Hastelloy.RTM. alloy, Monel.RTM. alloy, and combinations
thereof; and suitable plastics include, but are not limited to,
chlorinated polyvinyl chloride (CPVC) polymers, fiberglass
reinforced plastic (FRP), Kynar.RTM. polyvinylidene fluoride (PVDF)
polymers, polyethylene polymers, polypropylene polymers, polyvinyl
chloride (PVC) polymers, Teflon.RTM. perfluoroalkoxy (PFA)
polymers, Teflon.RTM. polytetrafluroethylene (PTFE) polymers, and
combinations thereof. For example, suitable tubing may be made of
Teflon.RTM. PFA or PTFE.
[0614] In an embodiment, the acid conditioning system (not shown)
may further comprise an acid flow meter (not shown). (See e.g.,
FIGS. 1A-1B: 177). The acid flow meter (not shown) may be fluidly
connected to tubing (not shown). (See e.g., FIGS. 1A-1B: 181). The
acid flow meter measures the flow rate of the acid solution.
[0615] The acid flow meter may be any suitable flow meter. Suitable
acid flow meters include, but are not limited to, paddlewheel,
ultrasonic vortex and insertion-type vortex flow meters. For
example, a suitable acid flow meter is available from ProMinent. In
an embodiment, the acid flow meter may be a Model DulcoFlow DFMa
from ProMinent with built-in signal transmission capability.
Second Optional Acid Conditioning System
[0616] In an embodiment, the system 1000, 1100 may further comprise
an acid conditioning system (not shown). (See e.g., FIG. 4: 460).
The acid conditioning system (not shown) comprises an acid tote
(not shown) and an acid metering pump (not shown). (See e.g., FIGS.
4: 460, 462 & 466).
[0617] The acid may be any suitable acid. Suitable acids include,
but are not limited to, hydrochloric acid and sulfuric acid. In an
embodiment, the acid may be hydrochloric acid (20 baume). In an
embodiment, the acid may be sulfuric acid (98%). In an embodiment,
the desired pH of the wastewater is about 6.5 or below to minimize
calcium carbonate scaling. In an embodiment, the amount of acid
solution added varies, depending on inlet water conditions (e.g.,
pH, alkalinity).
[0618] An outlet of the acid tote (not shown) may be fluidly
connected to an inlet of the acid metering pump (not shown) via
tubing (not shown); and an outlet of the acid metering pump (not
shown) may be fluidly connected to pipe (not shown) via tubing (not
shown). (See e.g., FIGS. 4: 422, 462, 464, 466 & 472).
[0619] The acid tote (not shown) may be any suitable acid tote or
other bulk chemical storage unit. (See e.g., FIG. 4: 462). Suitable
acid totes include, but are not limited to, an industry standard
shipping tote. For example, a suitable acid tote is available from
National Tank Outlet. In an embodiment, the acid tote may be a 275
gallon or a 330 gallon industry standard shipping tote.
[0620] The acid metering pump (not shown) may be any suitable acid
metering pump. (See e.g., FIG. 4: 466). Suitable acid metering
pumps include, but are not limited to, peristaltic pumps. For
example, a suitable acid metering pump is available from Blue-White
Industries, Inc., Cole Palmer Instrument Company and Watson Marlow.
In an embodiment, the acid metering pump may be a self-priming
peristaltic pump from Blue-White Industries, Inc.
[0621] The tubing (not shown) may be made of any suitable
corrosion-resistant tubing. (See e.g., FIGS. 4: 464 & 472). The
tubing may be made of any suitable corrosion-resistant metals or
plastics. Suitable metals include, but are not limited to, AL-6XN
alloy, Hastelloy .RTM. alloy, Monel.RTM. alloy and combinations
thereof; and suitable plastics include, but are not limited to,
chlorinated polyvinyl chloride (CPVC) polymers, fiberglass
reinforced plastic (FRP), Kynar.RTM. polyvinylidene fluoride (PVDF)
polymers, polyethylene polymers, polypropylene polymers, polyvinyl
chloride (PVC) polymers, Teflon.RTM. perfluoroalkoxy (PFA)
polymers, Teflon.RTM. polytetrafluroethylene (PTFE) polymers, and
combinations thereof. For example, suitable tubing may be made of
Teflon.RTM. PFA or PTFE.
[0622] In an embodiment, the acid conditioning system (not shown)
may further comprise an acid flow meter (not shown). (See e.g.,
FIGS. 4: 460 & 470). The acid flow meter (not shown) may be
fluidly connected to tubing (not shown). (See e.g., FIGS. 4: 470
& 472). The acid flow meter measures the flow rate of the acid
solution.
[0623] The acid flow meter (not shown) may be any suitable flow
meter. (See e.g., FIG. 4: 470). Suitable acid flow meters include,
but are not limited to, paddlewheel, ultrasonic vortex and
insertion-type vortex flow meters. For example, a suitable acid
flow meter is available from ProMinent. In an embodiment, the acid
flow meter may be a Model DulcoFlow DFMa from ProMinent with
built-in signal transmission capability.
First Optional Bactericide Conditioning System
[0624] In an embodiment, the system 1000, 1100 may further comprise
an optional bactericide conditioning system (not shown). (See e.g.,
FIGS. 1A-1B: 182). The bactericide conditioning system (not shown)
comprises a bactericide tote (not shown) and a bactericide metering
pump (not shown). (See e.g., FIGS. 1A-1B: 182, 183 & 185).
[0625] The bactericide may be any suitable bactericide. Suitable
bactericide includes, but is not limited to, bleach, bromine,
chlorine dioxide (generated), 2,2-dibromo-3-nitrilo-propionade
(DBNPA), glutaraldehyde, isothiazolin (1.5%) and ozone (generated).
In an embodiment, the bactericide may be selected from the group
consisting of bleach (12.5%), bromine, chlorine dioxide
(generated), DBNPA (20%), glutaraldehyde (50%), isothiazolin (1.5%)
and ozone (generated). In an embodiment, the desired bactericide
concentration is from about 10 ppm to about 1000 ppm (and any range
or value there between). The amount of bactericide solution added
to the wastewater varies, depending on inlet water condition.
[0626] An outlet of the bactericide tote (not shown) may be fluidly
connected to an inlet of the bactericide metering pump (not shown)
via tubing (not shown); and an outlet of the bactericide metering
pump (not shown) may be fluidly connected to the container 1039 or
to the pipe 1008 via tubing (not shown). (See e.g., FIGS. 1A-1B:
183, 184, 185 & 186).
[0627] The bactericide tote (not shown) may be any suitable
bactericide tote or other bulk chemical storage unit. (See e.g.,
FIGS. 1A-1B: 183). Suitable bactericide totes include, but are not
limited to, an industry standard shipping tote. For example, a
suitable bactericide tote is available from National Tank Outlet.
In an embodiment, the bactericide tote may be a 275 gallon or 330
gallon industry standard shipping tote. In an embodiment, the
bactericide tote may be a 55 gallon drum or a 5 gallon pail.
[0628] In an alternative embodiment, the bactericide tote (not
shown) may be replaced with a suitable bactericide generating
apparatus (not shown). (See e.g., FIGS. 1A-1B: 183). For example, a
suitable bactericide apparatus is available from Miox Corporation.
In an embodiment, the bactericide generating apparatus (not shown)
may be a Model AE-8 from Miox Corporation.
[0629] The bactericide metering pump (not shown) may be any
suitable bactericide metering pump. (See e.g., FIGS. 1A-1B: 185).
Suitable bactericide metering pumps include, but are not limited
to, electronic diaphragm, peristaltic and positive displacement
pumps. For example, a suitable bactericide metering pump is
available from Anko Products, Inc. In an embodiment, the
bactericide metering pump may be a self-priming peristaltic pump
from Anko Products, Inc. In an embodiment, the bactericide metering
pump may be a Mityflex Model 907 self-priming peristaltic pump from
Anko Products, Inc.
[0630] The tubing (not shown) may be made of any suitable
corrosion-resistant tubing. (See e.g., FIGS. 1A-1B: 184 & 186).
The tubing may be made of any suitable corrosion-resistant metals
or plastics. Suitable metals include, but are not limited to,
AL-6XN alloy, Hastelloy.RTM. alloy, Monel.RTM. alloy and
combinations thereof; and suitable plastics include, but are not
limited to, chlorinated polyvinyl chloride (CPVC) polymers,
fiberglass reinforced plastic (FRP), Kynar.RTM. polyvinylidene
fluoride (PVDF) polymers, polyethylene polymers, polypropylene
polymers, polyvinyl chloride (PVC) polymers, Teflon.RTM.
perfluoroalkoxy (PFA) polymers, Teflon.RTM. polytetrafluroethylene
(PTFE) polymers, and combinations thereof. In an embodiment, the
tubing may be made of Teflon.RTM. PFA or PTFE.
[0631] In an embodiment, the bactericide conditioning system (not
shown) may further comprise an optional bactericide flow meter (not
shown). (See e.g., FIGS. 1A-1B: 182). The bactericide flow meter
(not shown) may be fluidly connected to tubing (not shown). (See
e.g., FIGS. 1A-1B: 186). The bactericide flow meter measures the
flow rate of the bactericide solution.
[0632] The bactericide flow meter may be any suitable flow meter.
Suitable bactericide flow meters include, but are not limited to,
paddlewheel, ultrasonic vortex and insertion-type vortex flow
meters. For example, a suitable bactericide flow meter is available
from ProMinent. In an embodiment, the bactericide flow meter may be
a Model DulcoFlow DFMa from ProMinent with built-in signal
transmission capability.
Second Optional Bactericide Conditioning System
[0633] In an embodiment, the system 1000, 1100 may further comprise
a bactericide conditioning system (not shown). (See e.g., FIG. 4:
474). The bactericide conditioning system (not shown) comprises a
bactericide tote (not shown) and a bactericide metering pump (not
shown). (See e.g., FIGS. 4: 474, 476 & 480).
[0634] The bactericide may be any suitable bactericide. Suitable
bactericide includes, but is not limited to, bleach, bromine,
chlorine dioxide (generated), 2,2-dibromo-3-nitrilo-propionade
(DBNPA), glutaraldehyde, isothiazolin (1.5%) and ozone (generated).
In an embodiment, the bactericide may be selected from the group
consisting of bleach (12.5%), bromine, chlorine dioxide
(generated), DBNPA (20%), glutaraldehyde (50%), isothiazolin (1.5%)
and ozone (generated). In an embodiment, the desired bactericide
concentration is from about 10 ppm to about 1000 ppm (and any range
or value there between). The amount of bactericide solution added
to the wastewater varies, depending on inlet water condition.
[0635] An outlet of the bactericide tote (not shown) may be fluidly
connected to an inlet of the bactericide metering pump (not shown)
via tubing (not shown); and an outlet of the bactericide metering
pump (not shown) may be fluidly connected to pipe (not shown) via
tubing (not shown). (See e.g., FIGS. 4: 422, 476, 478, 480 &
482).
[0636] The bactericide tote (not shown) may be any suitable
bactericide tote or other bulk chemical storage unit. (See e.g.,
FIG. 4: 476). Suitable bactericide totes include, but are not
limited to, an industry standard shipping tote. For example, a
suitable bactericide tote is available from National Tank Outlet.
In an embodiment, the bactericide tote may be a 275 gallon or 330
gallon industry standard shipping tote.
[0637] In an alternative embodiment, the bactericide tote (not
shown) may be replaced with a suitable bactericide generating
apparatus (not shown). For example, a suitable bactericide
apparatus is available from Miox Corporation. In an embodiment, the
bactericide generating apparatus (not shown) may be a Model AE-8
from Miox Corporation.
[0638] The bactericide metering pump (not shown) may be any
suitable bactericide metering pump. (See e.g., FIG. 4: 480).
Suitable bactericide metering pumps include, but are not limited
to, peristaltic pumps. For example, a suitable bactericide metering
pump is available from Blue-White Industries, Inc., Cole-Palmer
Instrument Company and Watson Marlow. In an embodiment, the
bactericide metering pump may be a self-priming peristaltic pump
from Blue-White Industries, Inc.
[0639] The tubing (not shown) may be made of any suitable
corrosion-resistant tubing. (See e.g., FIGS. 478 & 482). The
tubing may be any suitable metal or plastic. Suitable metals
include, but are not limited to, AL-6XN alloy, Hastelloy.RTM.
alloy, Monel.RTM. alloy and combinations thereof and suitable
plastics include, but are not limited to, chlorinated polyvinyl
chloride (CPVC) polymers, fiberglass reinforced plastic (FRP),
Kynar.RTM. polyvinylidene fluoride (PVDF) polymers, polyethylene
polymers, polypropylene polymers, polyvinyl chloride (PVC)
polymers, Teflon.RTM. perfluoroalkoxy (PFA) polymers, Teflon.RTM.
polytetrafluroethylene (PTFE) polymers, and combinations thereof.
In an embodiment, the tubing may be made of Teflon.RTM. PFA or
PTFE.
[0640] In an embodiment, the bactericide conditioning system (not
shown) may further comprise a bactericide flow meter (not shown).
(See e.g., FIGS. 4: 474 & 484). The bactericide flow meter (not
shown) may be fluidly connected to tubing (not shown). (See e.g.,
FIGS. 4: 482 & 484). The bactericide flow meter measures the
flow rate of the bactericide solution.
[0641] The bactericide flow meter (not shown) may be any suitable
flow meter. (See e.g., FIG. 4: 484). Suitable bactericide flow
meters include, but are not limited to, paddlewheel, ultrasonic
vortex and insertion-type vortex flow meters. For example, a
suitable bactericide flow meter is available from ProMinent. In an
embodiment, the bactericide flow meter may be a Model DulcoFlow
DFMa from ProMinent with built-in signal transmission
capability.
Optional Scale Inhibition Conditioning System
[0642] In an embodiment, the system 1000, 1100 may further comprise
an optional scale inhibition conditioning system (not shown). (See
e.g., FIGS. 1A-1B: 187). The scale inhibition conditioning system
(not shown) comprises a scale inhibition tote (not shown) and a
scale inhibition metering pump (not shown). (See e.g., FIGS. 1A-1B:
187, 188 & 190).
[0643] The scale inhibitor may be any suitable scale inhibitor or
blend of scale inhibitors. A suitable scale inhibitor includes, but
is not limited to, inorganic phosphates, organophosphorous
compounds and organic polymers. In an embodiment, the scale
inhibitor may be selected from the group consisting of organic
phosphate esters, polyacrylates, phosphonates, polyacrylamides,
polycarboxylic acids, polymalates, polyphosphincocarboxylates,
polyphosphates and polyvinylsylphonates. In an embodiment, the
desired scale inhibitor concentration is from about 10 ppm to about
100 ppm (and any range or value there between). In an embodiment,
the desired scale inhibitor concentration is from about 2 ppm to
about 20 ppm (and any range or value there between). The amount of
scale inhibitor solution added to the wastewater varies, depending
on inlet water condition.
[0644] An outlet of the scale inhibition tote (not shown) may be
fluidly connected to an inlet of the scale inhibition metering pump
(not shown) via tubing (not shown); and an outlet of the scale
inhibition metering pump (not shown) may be fluidly connected to
container 1039 via tubing (not shown). (See e.g., FIGS. 1A-1B: 188,
190, 191).
[0645] The scale inhibition tote (not shown) may be any suitable
scale inhibition tote or other bulk chemical storage unit. Suitable
scale inhibition totes include, but are not limited to, an industry
standard shipping tote. (See e.g., FIGS. 1A-1B: 188). For example,
a suitable scale inhibition tote is available from National Tank
Outlet. In an embodiment, the scale inhibition tote may be a 275
gallon or 330 gallon industry standard shipping tote. In an
embodiment, the scale inhibition tote may be a 55 gallon drum or a
5 gallon pail.
[0646] The scale inhibition metering pump (not shown) may be any
suitable scale inhibitor metering pump. (See e.g., FIGS. 1A-1B:
190). Suitable scale inhibition metering pumps include, but are not
limited to, electronic diaphragm, peristaltic and positive
displacement pumps. For example, a suitable scale inhibition
metering pump is available from Anko Products, Inc. In an
embodiment, the scale inhibition metering pump may be a
self-priming peristaltic pump from Anko Products, Inc. In an
embodiment, the scale inhibition metering pump may be a Mityflex
Model 907 self-priming peristaltic pump from Anko Products,
Inc.
[0647] The tubing (not shown) may be made of any suitable
corrosion-resistant tubing. (See e.g., FIGS. 1A-1B: 189 & 191).
The tubing may be made of any suitable corrosion-resistant metals
or plastics. Suitable metals include but are not limited to,
plastic-coated carbon steel, stainless steel, super-duplex
stainless steel, AL-6XN alloy, Hastelloy.RTM. alloy, Monel.RTM.
alloy and combinations thereof; and suitable plastics include, but
are not limited to, chlorinated polyvinyl chloride (CPVC) polymers,
fiberglass reinforced plastic (FRP), Kynar.RTM. polyvinylidene
fluoride (PVDF) polymers, polyethylene polymers, polypropylene
polymers, polyvinyl chloride (PVC) polymers, Teflon.RTM.
perfluoroalkoxy (PFA) polymers, Teflon.RTM. polytetrafluroethylene
(PTFE) polymers, and combinations thereof. In an embodiment, the
tubing may be made of Teflon.RTM. PFA or PTFE.
[0648] In an embodiment, the scale inhibition conditioning system
(not shown) may further comprise an optional scale inhibition flow
meter (not shown). (See e.g., FIGS. 1A-1B: 187). The scale
inhibition flow meter may be fluidly connected to tubing (not
shown). (See e.g., FIGS. 1A-1B: 191). The scale inhibition flow
meter measures the flow rate of the scale inhibitor solution.
[0649] The scale inhibitor flow meter may be any suitable flow
meter. Suitable scale inhibitor flow meters include, but are not
limited to, paddlewheel, ultrasonic vortex and insertion-type
vortex flow meters. For example, a suitable scale inhibitor flow
meter is available from ProMinent. In an embodiment, the scale
inhibitor flow meter may be a Model DulcoFlow DFMa from ProMinent
with built-in signal transmission capability.
Optional Defoamer System
[0650] In an embodiment, the system 1000, 1100 may further comprise
an optional defoamer system (not shown). (See e.g., FIGS. 1A-1B:
192). The defoamer system (not shown) comprises a defoamer tote
(not shown) and a defoamer pump (not shown). (See e.g., FIGS.
1A-1B: 192, 193 & 195).
[0651] The defoamer may be any suitable defoamer. Suitable defoamer
includes, but is not limited to, alcohols, glycols, insoluable
oils, silicone polymers and stearates. In an embodiment, the
defoamer may be selected from the group consisting of fatty
alcohols, fatty acid esters, fluorosilicones, polyethylene glycol,
polypropylene glycol, silicone glycols and polydimethylsiloxane. In
an embodiment, the desired defoamer concentration is from about 10
ppm to about 100 ppm (and any range or value there between). In an
embodiment, the desired defoamer concentration is from about 2 ppm
to about 20 ppm (and any range or value there between). The amount
of defoamer solution added to the wastewater varies, depending on
inlet water condition.
[0652] An outlet of the defoamer tote (not shown) may be fluidly
connected to an inlet of the defoamer metering pump (not shown) via
tubing (not shown); and an outlet of the defoamer metering pump
(not shown) may be fluidly connected to container 1039 via tubing
(not shown). (See e.g., FIGS. 1A-1B: 193, 194, 195, 196).
[0653] The defoamer tote (not shown) may be any suitable defoamer
tote or other bulk chemical storage unit. (See e.g., FIGS. 1A-1B:
193). Suitable defoamer totes include, but are not limited to, an
industry standard shipping tote. For example, a suitable defoamer
tote is available from National Tank Outlet. In an embodiment, the
scale defoamer tote may be a 275 gallon or 330 gallon industry
standard shipping tote. In an embodiment, the defoamer tote may be
a 55 gallon drum or a 5 gallon pail.
[0654] The defoamer metering pump may be any suitable defoamer
metering pump. (See e.g., FIGS. 1A-1B: 195). Suitable defoamer
metering pumps include, but are not limited to, electronic
diaphragm, peristaltic, and positive displacement pumps. For
example, a suitable defoamer metering pump is available from Anko
Products, Inc. In an embodiment, the defoamer metering pump may be
a self-priming peristaltic pump from Anko Products, Inc. In an
embodiment, the defoamer metering pump may be a Mityflex Model 907
self-priming peristaltic pump from Anko Products, Inc.
[0655] The tubing (not shown) may be made of any suitable
corrosion-resistant tubing. (See e.g., FIGS. 1A-1B: 194 & 196).
The tubing may be made of any suitable corrosion-resistant metals
or plastics. Suitable metals include, but are not limited to,
plastic-coated carbon steel, stainless steel, super-duplex
stainless steel, AL-6XN alloy, Hastelloy.RTM. alloy, Monel.RTM.
alloy and combinations thereof; and suitable plastics include, but
are not limited to, chlorinated polyvinyl chloride (CPVC) polymers,
fiberglass reinforced plastic (FRP), Kynar.RTM. polyvinylidene
fluoride (PVDF) polymers, polyethylene polymers, polypropylene
polymers, polyvinyl chloride (PVC) polymers, Teflon.RTM.
perfluoroalkoxy (PFA) polymers, Teflon.RTM. polytetrafluroethylene
(PTFE) polymers, and combinations thereof. In an embodiment, the
tubing may be made of Teflon.RTM. PFA or PTFE.
[0656] In an embodiment, the defoamer conditioning system (not
shown) may further comprise an optional defoamer flow meter (not
shown). (See e.g., FIGS. 1A-1B: 192). The defoamer flow meter may
be fluidly connected to tubing (not shown). (See e.g., FIGS. 1A-1B:
196). The defomer flow meter measures the flow rate of the defoamer
solution.
[0657] The defoamer flow meter may be any suitable flow meter.
Suitable defoamer flow meters include, but are not limited to,
paddlewheel, ultrasonic vortex and insertion-type vortex flow
meters. For example, a suitable defoamer flow meter is available
from ProMinent. In an embodiment, the defoamer flow meter may be a
Model DulcoFlow DFMa from ProMinent with built-in signal
transmission capability.
Programmable Logic Controller or Other Computing Device for System
for Spray Evaporation of Water
[0658] In an embodiment, the system 100, 400, 1000, 1100 may
further comprise a programmable logic controller (PLC) or other
computing device 600. The PLC or computing device 600 may be any
suitable PLC or other computing device. For example, a suitable PLC
or other computing device 600 may be an Allan Bradley, Automation
Direct, Seimens, or WAGO logic controllers. Alternatively, the PLC
or other computing device 600 may be an engineered circuit
board.
[0659] In an embodiment, the system 100, 400, 1000, 1100 may have a
central programming logic controller (PLC) or other computing
device 600 that controls all functions of the unit in an autonomous
fashion from a central remote location. The PLC or other computing
device 600 may be capable of opening and closing all valve,
starting and stopping all pumps, monitoring all sensors and taking
all logical actions without human intervention during normal
operation. The PLC or other computing device 600 may be capable of
filling the system 100, 400, 1000, 1100 with wastewater, running
the system 100, 400, 1000, 1100 to evaporate the water, switching
the system 100, 400, 1000, 1100 to divert the concentrated waste to
a waste outlet, refilling the system 100, 400, 1000, 1100 with a
new batch of water and running the system 100, 400, 1000, 1100 to
continue the cycle. The PLC or other computing device 600 may be
capable of operating the system 100, 400, 1000, 1100 in a batch
process mode or in a "feed and bleed" mode. The PLC or other
computing device 600 may also be capable of automatically shutting
the system 100, 400, 1000, 1100 down during adverse conditions,
and, under certain circumstances, it may be capable of
automatically restarting the system 100, 400, 1000, 1100.
[0660] For example, the PLC or other computing device 600 may
automatically shut the system 100, 400, 1000, 1000 down in during
adverse conditions including, but not limited to, the following:
[0661] a high high sump level [0662] a high high containment level
[0663] a high high client tank level [0664] no wastewater feed is
available from client [0665] no water flow while a feed pump or a
recirculation pump is running [0666] no water pressure while a feed
pump or a recirculation pump is running [0667] no air flow when a
fan is running [0668] a motor overload fault has occurred [0669] a
VFD fault has occurred [0670] a loss of power has occurred [0671] a
loss of natural gas pressure has occurred [0672] an emergency stop
(Estop) is engaged [0673] an extreme low ambient temperature
[0674] For example, the PLC or other computing device 600 may also
automatically restart the system 100, 400, 1000, 1100 down in
certain conditions including, but not limited to, the following:
[0675] the loss of natural gas pressure is only temporary [0676] a
Gen set goes down
[0677] If the Gen set goes down, the PLC or other computing device
600 may attempt to restart the Gen set; and, if the Gen set
restarts, the PLC or other computing device 600 may attempt to
restart the system 100, 400, 1000, 1100.
[0678] Further, the PLC or other computing device 600 may be used
by an operator to manually override a programmed function of the
system 100, 400, 1000, 1100 to allow any aspect of the system 100,
400, 1000, 1100 to be controlled manually (e.g., opening and
closing valves, or starting and stopping pumps) for maintenance and
troubleshooting purposes.
[0679] In an embodiment, the system 100, 400, 1000, 1100 may have
the capability to remotely read and write to the central PLC or
other computing device 600 that allows for full reporting of the
system's 100, 400, 1000, 1100 operating conditions to a central
remote location and/or that allows full control of the system's
100, 400, 1000, 1100 operating conditions from the central remote
location. In an embodiment, the system 100, 400, 1000, 1100 may
have the capability to send information/communications to the PLC
or other computing device 600 at the central remote location. In an
embodiment, the system 100, 400, 1000, 1100 may have the capability
to send communications (e.g., to report error codes, inlet volumes,
outlet volumes, etc.) to the PLC or other computing device 600 at
the central remote location via a satellite antenna and modem or
other communication technologies.
[0680] In an embodiment, the system 100, 400, 1000, 1100 may have
the capability to receive commands/communications from the PLC or
other computing device 600 at the central remote location. In an
embodiment, the system 100, 400, 1000, 1100 may have the capability
to receive commands/communications (e.g., to alter the operational
behavior of the system 100, 400, 1000, 1100) from the PLC or other
computing device 600 at the central remote location via the
satellite antenna and modem or other communication
technologies.
[0681] Any suitable satellite antenna and modem may be used. For
example, a suitable satellite antenna and modem is available from
Inmarsat.
[0682] Other communication technologies include, but are not
limited to, any other satellite-based communication technology, any
Mobile Data mode (e.g., LTE/4G), any radio- or laser-transmitted
communication array or any hard-wired internet connection.
[0683] For example, the system 100, 400, 1000, 1100 may send
communications to the PLC or other computing device 600 including,
but not limited to, the following: [0684] number of barrels of
wastewater pumped into the system [0685] number of barrels of
concentrated waste pumped out of the system [0686] ambient
temperature and/or ambient humidity conditions at the system [0687]
alarms for abnormal system behavior [0688] current operating mode
[0689] inlet pressure of natural gas [0690] client tank levels
[0691] current system settings (e.g., burner setting, cold weather
set points, target evaporation percentage, minimum water level,
maximum water level, etc.)
[0692] For example, the system 100, 400, 1000, 1100 may receive
commands/communications from the PLC or other computing device 600
including, but not limited to, the following: [0693] a stop command
[0694] a start command [0695] a clear command for alarms [0696] an
air, argon or nitrogen purge command for cold weather conditions
[0697] an increase or decrease command for burner temperature set
point [0698] an increase or decrease command(s) for acid pump,
bactericide pump, defoamer pump and/or scale inhibitor pump dosage
rates [0699] an increase or decrease command for evaporation
percentage (i.e., number of barrels evaporated divided by number of
barrels available) [0700] an increase or decrease command(s) for
water level settings (e.g., low low, operating low, operating high,
high high)
[0701] With reference to FIG. 6, the PLC or computing device 600 of
the system 100, 400, 1000, 1100 may include a bus 610 that directly
or indirectly couples the following devices: memory 612, one or
more processors 614, one or more presentation components 616, one
or more input/output (I/O) ports 618, I/O components 620, a user
interface 622 and an illustrative power supply 624, and a battery
backup (not shown). In an embodiment, the shut-off valve 106, the
first pressure switch 110, the first (feed) valve 112, the first
limit switch 113, the second limit switch 114, the first pump 118,
the first flow meter 122, the first temperature sensor, 130, the
first conductivity meter 131, the second conductivity meter 132
(not shown), the air temperature sensor 140, the air blower 142,
the air heater with fan 143, the first high differential pressure
switch 147, the second high, high differential pressure switch 148,
the first high, high limit switch 149, the low limit switch 150,
the high limit switch 151, a second high, high limit switch 152,
the second pump 156, the second pressure switch 159, the pH meter
161, the second (recycle) valve 166, the third limit switch 167,
the fourth limit switch 168, the third (discharge) valve 169, the
fifth limit switch 170, the sixth limit switch 171, the second flow
meter 173, the third shut-off valve 174, the acid metering pump
180, the acid flow meter (not shown), the bactericide metering pump
185, the bactericide flow meter (not shown), the scale inhibition
metering pump 190, the scale inhibition flow meter (not shown), the
defoamer pump 195, and/or the defoamer flow meter (not shown)
couple directly or indirectly to a signal conditioning device. If
the component's raw signal must be processed to provide a suitable
signal for an I/O system, that component will couple indirectly to
the signal conditioning device.
[0702] In another embodiment, the shut-off valve 406, 506, the
first conductivity meter 410, 510, the first flow meter 412, 512,
the hygrometer 414, the first 3-way valve 416, the pump 420, 520,
the pressure sensor 425, the second conductivity meter 428, 528,
the pH meter 430, the second 3-way valve 432, 532, the air blower
436, 536 (or the plurality of air blowers 436', 436''), the
differential pressure sensor 445, the first temperature sensor 590,
the second temperature sensor 592, the high-water level switch (not
shown), the low-water level switch (not shown), the second flow
meter 456, the acid metering pump 466, the acid flow meter 470, the
bactericide metering pump 480 and/or the bactericide flow meter 484
couple directly or indirectly to a signal conditioning device. If
the component's raw signal must be processed to provide a suitable
signal for an I/O system, that component will couple indirectly to
the signal conditioning device.
[0703] In an embodiment, the shut-off valve 1006, the first
pressure switch (not shown) (see FIGS. 1A-1B: 110), the first
(feed) valve 1012, the first limit switch (not shown) (see FIGS.
1A-1B: 113), the second limit switch (not shown) (see FIGS. 1A-1B:
114), the pump 1018, the flow indicator or meter 1022, the first
temperature sensor (not shown) (see FIGS. 1A-1B: 130), the first
conductivity meter (not shown) (see FIGS. 1A-1B: 131), the second
conductivity meter (not shown), the air temperature sensor (not
shown) (see FIGS. 1A-1B: 140), the first air blower 1042, the
second air blower (not shown), the air preheater 1043, the first
high differential pressure switch 1053, the second high
differential pressure switch (not shown) (see FIGS. 1A-1B: 147),
the third high, high differential pressure switch (not shown) (see
FIGS. 1A-1B: 148), the first high, high limit switch 1049 (see
FIGS. 1A-1B: 149), the low limit switch (not shown) (see FIGS.
1A-1B: 150), the high limit switch (not shown) (see FIGS. 1A-1B:
151), a second high, high limit switch (not shown) (see FIGS.
1A-1B: 152), the pH meter (not shown) (see FIGS. 1A-1B: 161), the
third (discharge) valve 1069, the third limit switch (not shown)
(see FIGS. 1A-1B: 170), the fourth limit switch (not shown) (see
FIGS. 1A-1B: 171), the third flow indicator or meter 1073 (see
FIGS. 1A-1B: 173, the third shut-off valve (not shown) (see FIGS.
1A-1B: 174), the acid metering pump (not shown) (see FIGS. 1A-1B:
180 & 4: 466), the acid flow meter (not shown) (see FIG. 4:
470), the bactericide metering pump (not shown) (see FIGS. 1A-1B:
185 & 4: 480), the bactericide flow meter (not shown) (see FIG.
4: 484), the scale inhibition metering pump (not shown) (see FIGS.
1A-1B: 190), the scale inhibition flow meter (not shown), the
defoamer pump (not shown) (see FIGS. 1A-1B: 195), and/or the
defoamer flow meter (not shown) couple directly or indirectly to a
signal conditioning device. If the component's raw signal must be
processed to provide a suitable signal for an I/O system, that
component will couple indirectly to the signal conditioning
device.
[0704] The bus 610 represents what may be one or more busses (such
as an address bus, data bus, or combination thereof). Although the
various blocks of FIG. 6 are shown with lines for the sake of
clarity, in reality, delineating various components is not so
clear, and metaphorically, the lines would more accurately be
fuzzy. For example, one may consider a presentation component such
as a display device to be an I/O component. Additionally, many
processors have memory. The inventors recognize that such is the
nature of the art, and reiterate that the diagram of FIG. 6 is
merely illustrative of an exemplary computing device that can be
used in connection with one or more embodiments of the present
invention. Further, a distinction is not made between such
categories as "workstation," "server," "laptop," "mobile device,"
etc., as all are contemplated within the scope of FIG. 6 and
reference to "computing device."
[0705] The PLC or computing device 600 of the system 100, 400,
1000, 1100 typically includes a variety of computer-readable media.
Computer-readable media can be any available media that can be
accessed by the PLC or computing device 600 and includes both
volatile and nonvolatile media, removable and non-removable media.
By way of example, and not limitation, computer-readable media may
comprise computer-storage media and communication media. By way of
another example, and not limitation, computer readable media may
also comprise radio, cellular, or satellite communication media for
remote collection and/or manipulation of data contained within the
PLC or computing device 600. The computer-storage media includes
volatile and nonvolatile, removable and non-removable media
implemented in any method or technology for storage of information
such as computer-readable instructions, data structures, program
modules or other data. Computer-storage media includes, but is not
limited to, Random Access Memory (RAM), Read Only Memory (ROM),
Electronically Erasable Programmable Read Only Memory (EEPROM),
flash memory or other memory technology, CD-ROM, digital versatile
disks (DVD) or other holographic memory, magnetic cassettes,
magnetic tape, magnetic disk storage or other magnetic storage
devices, or any other medium that can be used to encode desired
information and which can be accessed by the PLC or computing
device 600.
[0706] The memory 612 includes computer-storage media in the form
of volatile and/or nonvolatile memory. The memory 612 may be
removable, non-removable, or a combination thereof. Suitable
hardware devices include solid-state memory, hard drives,
optical-disc drives, etc. The PLC or computing device 600 includes
one or more processors 614 that read data from various entities
such as the memory 612 or the I/O components 620.
[0707] The presentation component(s) 616 present data indications
to a user or other device. In an embodiment, the PLC or computing
device 600 outputs present data indications including
conductivity(ies), differential pressure(s), flow rate(s),
humidity, pH, pressure, temperature and/or the like to a
presentation component 616. Suitable presentation components 616
include a display device, speaker, printing component, vibrating
component, and the like.
[0708] The user interface 622 allows the user to input/output
information to/from the PLC or computing device 600. Suitable user
interfaces 622 include keyboards, key pads, touch pads, graphical
touch screens, and the like. In some embodiments, the user
interface 622 may be combined with the presentation component 616,
such as a display and a graphical touch screen. In some
embodiments, the user interface 622 may be a portable hand-held
device. The use of such devices is well-known in the art.
[0709] In an embodiment, the one or more I/O ports 618 allow the
PLC or computing device 600 to be logically coupled to other
devices including the shut-off valve 106, the first pressure switch
110, a first (feed) valve 112, the first limit switch 113, the
second limit switch 114, the first pump 118, the first flow meter
122, the first temperature sensor 130, the first conductivity meter
131, the second conductivity meter 132 (not shown), the air
temperature sensor 140, the air blower 142, the air heater with fan
143, the first high differential pressure switch 147, the second
high, high differential pressure switch 148, the first high, high
limit switch 149, the low limit switch 150, the high limit switch
151, a second high, high limit switch 152, the second pump 156, the
second pressure switch 159, the pH meter 161, the second (recycle)
valve 166, the third limit switch 167, the fourth limit switch 168,
the third (discharge) valve 169, the fifth limit switch 170, the
sixth limit switch 171, the second flow meter 173, the third
shut-off valve 174, the acid metering pump 180, the acid flow meter
(not shown), the bactericide metering pump 185, the bactericide
flow meter (not shown), the scale inhibition metering pump 190, the
scale inhibition flow meter (not shown), the defoamer pump 195,
and/or the defoamer flow meter (not shown), and other I/O
components 620, some of which may be built in. Examples of other
I/O components 620 include a printer, scanner, wireless device, and
the like.
[0710] In another embodiment, the one or more I/O ports 618 allow
the PLC or computing device 600 to be logically coupled to other
devices including the shut-off valve 406, 506, the first
conductivity meter 410, 510, the first flow meter 412, 512, the
hygrometer 414, the first 3-way valve 416, the pump 420, 520, the
pressure sensor 425, the second conductivity meter 428, 528, the pH
meter 430, the second 3-way valve 432, 532, the air blower 436, 536
(or the plurality of air blowers 436', 436''), the differential
pressure sensor 445, the first temperature sensor 590, the second
temperature sensor 592, the high-water level switch (not shown),
the low-water level switch (not shown), the second flow meter 456,
the acid metering pump 466, the acid flow meter 470, the
bactericide metering pump 480 and/or the bactericide flow meter
484, and other I/O components 620, some of which may be built in.
Examples of other I/O components 620 include a printer, scanner,
wireless device, and the like.
[0711] In an embodiment, the one or more I/O ports 618 allow the
PLC or computing device 600 to be logically coupled to other
devices including the shut-off valve 1006, the first pressure
switch (not shown) (see FIGS. 1A-1B: 110), a first (feed) valve
1012, the first limit switch (not shown) (see FIGS. 1A-1B: 113),
the second limit switch (not shown) (see FIGS. 1A-1B: 114), the
pump 1018, the first flow indicator or meter 1022, the first
temperature sensor (not shown) (see FIGS. 1A-1B: 130), the first
conductivity meter (not shown) (see FIGS. 1A-1B: 131), the second
conductivity meter (not shown), the air temperature sensor 1040
(see FIGS. 1A-1B: 140), the first air blower 1042, the second air
blower (not shown), the air preheater 1043, the first high
differential pressure switch 1053, the second high differential
pressure switch (not shown) (see FIGS. 1A-1B: 147), the second
high, high differential pressure switch (not shown) (see FIGS.
1A-1B: 148), the first high, high limit switch (not shown) (see
FIGS. 1A-1B: 149), the low limit switch (see FIGS. 1A-1B: 150), the
high limit switch (not shown) (see FIGS. 1A-1B: 151), a second
high, high limit switch (not shown) (see FIGS. 1A-1B: 152), the pH
meter (not shown) (see FIGS. 1A-1B: 161), the third (discharge)
valve 1069, the third limit switch (not shown) (see FIGS. 1A-1B:
170), the fourth limit switch (not shown) (see FIGS. 1A-1B: 171),
the third flow indicator or meter 1073 (see FIGS. 1A-1B: 173), the
second shut-off valve (not shown) (see FIGS. 1A-1B: 174), the acid
metering pump (not shown) (see FIGS. 1A-1B: 180 & 4: 466), the
acid flow meter (not shown) (see FIG. 4: 470), the bactericide
metering pump (not shown) (see FIGS. 1A-1B: 185 & 4: 480), the
bactericide flow meter (not shown) (see FIG. 4: 484), the scale
inhibition metering pump (not shown) (see FIGS. 1A-1B: 190), the
scale inhibition flow meter (not shown), the defoamer pump (not
shown) (see FIGS. 1A-1B: 195), and/or the defoamer flow meter (not
shown), and other I/O components 620, some of which may be built
in. Examples of other I/O components 620 include a printer,
scanner, wireless device, and the like.
[0712] In an embodiment (see FIGS. 1A-3), the PLC or computing
device 600 controls the two-pump system 100 according to the
following circumstances:
[0713] To initiate the process, the following occurs: [0714]
Initially, an air temperature sensor 140 is set to a predetermined
minimum air temperature (e.g., typically from about 25.degree. F.
to about 35.degree. F.). If the air temperature sensor 140 is
activated, the system 100 will stop operations due to an inability
of the air heater with fan 143 to raise the wastewater temperature
in the sump (bottom) of the container 139, 339 above the freezing
point. [0715] Initially, the first (feed) valve 112 is in a CLOSED
position. To begin processing wastewater, the first (feed) valve
112 is switched to the OPEN position, allowing the feedstock water
to enter the first pump 118. In an embodiment, the first limit
switch 113 confirms that the first (feed) valve 112 is OPEN; and
the second limit switch 114 confirms that the first (feed) valve
112 is CLOSED. [0716] The first pump 118 is started to fill the
sump (bottom) of the container 139, 339 with an initial fill volume
of wastewater. To aid the second (recycle) pump 156, the container
139, 339 is set at forward incline to allow maximum depth at the
suction-end (front) of the container 139, 339 to provide minimal
sump volume. If the first conductivity meter 131 measures a
predetermined minimum conductivity (e.g., indicating presence of
oil in feedwater), the system 100 is shut off. [0717] When the high
limit switch 151 (at an operational level) is activated, the first
(feed) valve 112 is switched to the CLOSED position; and the first
pump 118 is shut off. In an embodiment, the second limit switch 114
confirms that the first (feed) valve 112 is CLOSED. If the first
high, high limit switch 149 (at a primary containment level) is
activated, the first (feed) valve 112 and the second (recycle)
valve 166 are switched to the CLOSED positions; and the first pump
118 and the second pump 156 are shut off to prevent overfilling of
the sump (bottom) of the container 139, 339. In an embodiment, the
second limit switch 114 confirms that the first (feed) valve 112 is
CLOSED; and the third limit switch 167 confirms that the second
(recycle) valve is CLOSED. If the second high, high limit switch
152 (at a secondary containment level) is activated, an alarm is
sent to the PLC or computing device 600. Further, the first (feed)
valve 112 and the second (recycle) valve 166 are switched to the
CLOSED positions; and the first pump 118 and the second pump 156
are shut off to prevent overfilling of the sump (bottom) of the
container 139, 339. In an embodiment, the second limit switch 114
confirms that the first (feed) valve 112 is CLOSED; and the third
limit switch 167 confirms that the second (recycle) valve is
CLOSED. [0718] Optionally, acid may be added to the sump (bottom)
of the container 139, 339 or to the pipe 154 via the acid
conditioning system 177, bactericide may be added to the sump
(bottom) of the container 139, 339 or to the pipe 154 via the
bactericide conditioning system 182, scale inhibitor may be added
to the sump of the container or to the pipe 154 via the scale
inhibition system and/or defoamer may be added to the sump (bottom)
of the container 139, 339 or to the pipe 154 via the defoamer
system 192 based on the initial fill volume. [0719] The air blower
142 is started. If the first high differential pressure switch 147
is activated, the air blower 142 is operating. If a flame is
present in the natural gas burner, the air heater with fan 143 is
started. [0720] Initially, the second (recycle) valve 166 is in a
CLOSED position. To allow recirculating wastewater to enter the
spray system 134, 334, the second (recycle) valve 166 is switched
to the OPEN position. In an embodiment, the third limit switch 167
confirms that the second (recycle) valve 166 is CLOSED; and the
fourth limit switch 168 confirms that the second (recycle) valve
166 is OPEN. [0721] Initially, the third (discharge) valve 169 is
in a CLOSED position. In an embodiment, the fifth limit switch 170
confirms that the third (discharge) valve 169 is OPEN; and the
sixth limit switch 171 confirms that the third (discharge) valve
169 is CLOSED. [0722] The second pump 156 is started to recirculate
the wastewater from the sump (bottom) of the container 139, 339
through the spray system 134, 334. If the second pressure switch
159 is activated, a minimum pressure has been obtained. If the
first conductivity sensor/meter 131 measures a predetermined low
conductivity (e.g., indicating presence of oil in recycle
wastewater), the system 100 is shut off. [0723] Optionally, acid
may be added to the sump (bottom) of the container 139, 339 or to
the pipe 154 via the acid conditioning system 177, bactericide may
be added to the sump (bottom) of the container 139, 339 or to the
pipe 154 via the bactericide conditioning system 182, scale
inhibitor may be added to the sump of the container 139, 339 or to
the pipe 154 via the scale inhibition system and/or defoamer may be
added to the sump (bottom) of the container 139, 339 or to the pipe
154 via the defoamer system 192 based on wastewater condition as
indicated by pH meter 161, the first conductivity meter 131, and/or
the second conductivity meter 132 (not shown).
[0724] If the low limit switch 150 is activated, the following
occurs: [0725] To continue processing wastewater, the first (feed)
valve 112 is switched to the OPEN position, allowing the feedstock
water to enter the first pump 118. In an embodiment, the first
limit switch 113 confirms that the first (feed) valve 112 is OPEN.
[0726] The first pump 118 is started to fill the sump (bottom) of
the container 139, 339 with an initial fill volume of wastewater.
If the first conductivity sensor/meter 131 measures a predetermined
minimum conductivity (e.g., indicating presence of oil in
feedwater), the system 100 is shut off. [0727] When the high limit
switch 151 (at an operational level) is activated, the first (feed)
valve 112 is switched to the CLOSED position; and the first pump
118 is shut off. In an embodiment, the second limit switch 114
confirms that the first (feed) valve 112 is CLOSED. [0728]
Optionally, acid may be added to the sump (bottom) of the container
139, 339 or to the pipe 154 via the acid conditioning system 177,
bactericide may be added to the sump (bottom) of the container 139,
339 or to the pipe 154 via the bactericide conditioning system 182,
scale inhibitor may be added to the sump (bottom) of the container
139, 339 or to the pipe 154 via the scale inhibition system and/or
defoamer may be added to the sump (bottom) of the container 139,
339 or to the pipe 154 via the defoamer system 192 based on the
initial fill volume. [0729] If the second conductivity meter 132
indicates the brine has reached a predetermined maximum
conductivity, the following occurs: [0730] To begin discharging
brine, the third (discharge) valve 169 is switched to the OPEN
position, allowing the brine to discharge from the waste outlet
176. In an embodiment, the fifth limit switch 170 confirms that the
third (discharge) valve 169 is OPEN. [0731] To prevent recycle of
brine, the second (recycle) valve 166 is switched to the CLOSED
position. In an embodiment, the third limit switch 167 confirms
that the second (recycle) valve 166 is CLOSED. [0732] When the
second pressure switch 159 indicates a loss of pressure due to
nearly complete discharge of brine from the discharge outlet 176,
the second pump 156 will begin to lose prime. [0733] To allow
recycle of residual brine, the second (recycle) valve 166 is
switched to the OPEN position. In an embodiment, the fourth limit
switch 168 confirms that the second (recycle) valve 166 is OPEN.
[0734] To stop discharge of brine, the third (discharge) valve 169
is switched to the CLOSED position. In an embodiment, the fifth
limit switch 171 confirms that the third (discharge) valve 169 is
CLOSED. [0735] To continue processing wastewater, the first (feed)
valve 112 is switched to the OPEN position, allowing the feedstock
water to enter the first pump 118. In an embodiment, the first
limit switch 113 confirms that the first (feed) valve 112 is OPEN.
[0736] The first pump 118 is started to fill the sump (bottom) of
the container 139, 339 with an initial fill volume of wastewater.
If the first conductivity sensor/meter 131 measures a predetermined
minimum conductivity (e.g., indicating presence of oil in
feedwater), the system 100 is shut off. [0737] When the high limit
switch 151 (at an operational level) is activated, the first (feed)
valve 112 is switched to the CLOSED position; and the first pump
118 is shut off. In an embodiment, the second limit switch 114
confirms that the first (feed) valve 112 is CLOSED. [0738]
Optionally, acid may be added to the sump (bottom) of the container
139, 339 or to the pipe 154 via the acid conditioning system 177,
bactericide may be added to the sump (bottom) of the container 139,
339 or to the pipe 154 via the bactericide conditioning system 182,
scale inhibitor may be added to the sump (bottom) of the container
139, 339 or to the pipe 154 via the scale inhibition system and/or
defoamer may be added to the sump (bottom) of the container 139,
339 or to the pipe 154 via the defoamer system 192 based on the
initial fill volume. [0739] The system 100 runs continuously until
shut off by an operator or by PLC or computing device 600 due to
occurrence of one of the above-discussed situations. In an
embodiment, the PLC or computing device 600 monitors hygrometer 414
(e.g., barometric pressure, humidity, temperature) and controls
operating conditions of the system 100 to maximize evaporation
through the control of droplet size created by the spray system
134, 334 and air volume provided through the air blower and heater
system 141, 241, 341, as discussed below.
[0740] In an embodiment, the PLC or computing device 600 monitors
the pH meter 161 and controls the addition of acid introduced to
the water to condition it for the prevention of scale (scaling), as
discussed below.
[0741] In an embodiment, the PLC or computing device 600 controls
the addition of bactericide introduced to the water to condition it
for the prevention of microbial (e.g., algae, bacteria) growth, as
discussed below.
[0742] In an embodiment, the PLC or computing device 600 controls
the addition of scale inhibitor introduced to the water to
condition it for the prevention of scale (e.g., mineral) build up,
as discussed below.
[0743] In an embodiment, the PLC or computing device 600 controls
the addition of defoamer introduced to the water to condition it
for the prevention of foam, as discussed below.
[0744] In another embodiment (see FIGS. 4A-5D), the PLC or
computing device 600 controls the first three-way valve 416 of the
single pump system 400 according to the following circumstances:
[0745] If the low-water level switch (not shown) in the container
444, 544 is activated, the first 3-way valve 416 diverts suction of
the pump 420, 520 to a water inlet 404, 504, allowing connection to
a wastewater suction header 402. The first 3-way valve 416 will
remain in this state until a high-water level switch (not shown) in
the container 444, 544 is activated. [0746] When the high-water
level switch (not shown) in the container 444, 544 is activated,
the first 3-way valve 416 diverts suction of the pump 420, 520 to a
draw line 452, 552 for the container 444, 544, providing for a
recycle of the water in the container 444, 544 through the spray
system 440.
[0747] Further, the PLC or computing device 600 controls the second
3-way valve 432, 532 on the discharge side of the pump 420, 520
according to the following circumstances: [0748] By default, the
second 3-way valve 432, 532 will divert the discharge of water to
the spray system 440. [0749] If the conductivity of water in the
conductivity meter 428, 528 reaches a predetermined maximum
conductivity, the second 3-way valve 432, 532 will divert discharge
of the concentrated waste to the waste outlet 458, 558 of the
container 444, 544, allowing connection to an external waste
disposal storage (e.g., tank, truck or pond) (not shown). The
second 3-way valve 432, 532 will remain in this position until the
low-water level switch (not shown) in the container 444, 544 is
activated. At which point, the second 3-way valve 432, 532 is
returned to its default position.
[0750] In an embodiment, the PLC or computing device 600 monitors
hygrometer 414 (e.g., barometric pressure, humidity, temperature)
and controls operating conditions of the system 400 to maximize
evaporation through the control of droplet size created by the
spray system 440 and air volume provided through the air blower
system 434, 534, as discussed below.
[0751] In an embodiment, the PLC or computing device 600 monitors
the pH meter and controls the addition of acid introduced to the
water to condition it for the prevention of scale (e.g., mineral)
build up, as discussed below.
[0752] In an embodiment, the PLC or computing device 600 controls
the addition of bactericide introduced to the water to condition it
for the prevention of microbial (e.g., algae, bacteria) growth, as
discussed below.
[0753] In another embodiment (see FIGS. 10A-10C & 11A-11F), the
PLC or computing device 600 controls the first (feed) shut-off
valve 1006, the first (feed) valve 1012 and the second
(feed/recirculating) valve 1054 of the single pump system 1000,
1100 according to the following circumstances: [0754] If an
optional low-water level (not shown) in the container 1039 is
activated or if the first (feed) shut-off valve 1006 and the first
(feed) valve 1012 are switched to the OPEN position (and the third
(pump supply) valve 1055 is switched to the CLOSED position), the
first (feed) shut-off valve 1006 and the first (feed) valve 1012
diverts suction of a pump 1018 to a flange to a water source or
water inlet 1004, allowing connection to a wastewater suction
header 1002. The first (feed) shut-off valve 1006 and the first
(feed) valve 1012 will remain in this state until an optional
high-water switch (not shown) is activated or until the first
(feed) shut-off valve 1006 and the first (feed) valve 1012 are
switched to a CLOSED position.
[0755] Further, the PLC or computing device 600 controls the second
(feed/recirculating) valve 1054 of the single pump system 1000,
1100 according to the following circumstances: [0756] If the second
(feed/recirculating) valve 1054 is switched to the OPEN position
(and the fourth (discharge) valve 1069 is switched to the CLOSED
position), the second (feed/recirculating) valve 1054 will divert
the discharge of water from the pump 1018 to the manifold 1028 or
the drip system 1034. The second (feed/recirculating) valve 1054
will remain in this state until the second (feed/recirculating)
valve 1054 is switched to the CLOSED position.
[0757] Further, the PLC or computing device 600 controls the third
(pump supply) valve 1055 of the single pump system 1000, 1100
according to the following circumstances: [0758] If the third (pump
supply) valve 1055 is switched to the OPEN position (and the first
(feed) valve 1012 and the fourth (discharge valve 1069 are switched
to the CLOSED position), the third (pump supply) valve 1055 diverts
suction of a pump 1018 to a draw line 1055a, providing for
recirculation of the condensed water in the container 1039 through
the drip system 1034. The third (pump supply) valve 1055 will
remain in this state until the third (pump supply) valve 1055 is
switched to the CLOSED position.
[0759] Further, the PLC or computing device 600 controls a fourth
(discharge) valve 1069 of the single pump system 1000, 1100
according to the following circumstances: [0760] If the
conductivity of water in an optional second conductivity meter (not
shown) reaches a predetermined maximum conductivity, the fourth
(discharge) valve 1069 is switched to the OPEN position to divert
discharge of the concentrated waster to a waste flange or discharge
outlet 1076, allowing connection to an external waste disposal
storage (e.g., tank, truck or pond). (See e.g., FIGS. 10A &
10C). The fourth (discharge) valve 1069 will remain in this
position until an optional low level switch (not shown) in the
container 1039 is activated. At which point, the fourth (discharge)
valve 1069 is switched to the CLOSED position. [0761] If the fourth
(discharge) valve 1069 is switched to the OPEN position, the fourth
(discharge) valve 1069 will divert discharge of the concentrated
waster to a waste flange or discharge outlet 1076, allowing
connection to an external waste disposal storage (e.g., tank, truck
or pond). (See e.g., FIGS. 10A & 10C). The fourth (discharge)
valve 1069 will remain in this position until the fourth
(discharge) valve 1069 is switched to the CLOSED position.
[0762] In an embodiment, the PLC or computing device 600 controls
the natural gas flow to the air preheater 1043 burner to control a
resulting air temperature based on an ambient air temperature and a
desired evaporation rate. In an embodiment, the natural gas flow
control valve may be modulated from a fully OPEN position to a
fully CLOSED position, and vice versa.
[0763] In an embodiment, the PLC or computing device 600 monitors
hygrometer (e.g., barometric pressure, humidity, temperature) and
controls operating conditions of the system 1000, 1100 to maximize
evaporation through the control of droplet size created by the drip
system 1034 and air volume provided through the air blower and
preheater system 1041, as discussed below.
[0764] In an embodiment, the PLC or computing device 600 monitors
the pH meter and controls the addition of acid introduced to the
water to condition it for the prevention of scale (scaling), as
discussed below.
[0765] In an embodiment, the PLC or computing device 600 controls
the addition of bactericide introduced to the water to condition it
for the prevention of microbial (e.g., algae, bacteria) growth, as
discussed below.
[0766] In an embodiment, the PLC or computing device 600 controls
the addition of scale inhibitor introduced to the water to
condition it for the prevention of scale (e.g., mineral) build up,
as discussed below.
[0767] In an embodiment, the PLC or computing device 600 controls
the addition of defoamer introduced to the water to condition it
for the prevention of foam, as discussed below.
Method for Using System for Spray Evaporation of Water
[0768] A flow diagram for a method 700 of using a system for spray
evaporation of water is shown in FIGS. 7A-7B. In an embodiment, the
method 700 comprises selecting predetermined parameters (e.g., air
flow rate, air heating rate, maximum conductivity, maximum
humidity, maximum pH, minimum air temperature, minimum pH, water
flow rate, water droplet size) for a system for spray evaporation
of water, drawing wastewater into the system from an external water
source using a first pump and a first valve, diverting the
wastewater to a spray nozzle, spraying the wastewater through the
spray nozzle to create water droplets, spraying the water droplets
into a container of the system along with a large volume of air,
collecting condensed water in the sump (bottom) of the container,
recycling condensed water from the bottom of the container using a
second pump and a second valve, and diverting the concentrated
waste to a waste outlet using a third valve, as illustrated in
FIGS. 7A-7B.
[0769] In an embodiment, the method 700 comprises a step 702 of
selecting predetermined parameters (e.g., maximum conductivity,
water droplet size, air flow rate, air heating rate, water flow
rate, maximum humidity) for the system of spray evaporation of
water. In an embodiment, the maximum conductivity may be about
1,000 micro .mu.S/cm to about 400,000 .mu.S/cm (and any range or
value there between). In an embodiment, the water droplet size may
be about 50 .mu.m to about 1,000 .mu.m (and any range or value
there between). In an embodiment, the air flow rate may be about
60,000 cubic feet per minute (CFM) to about 150,000 CFM (and any
range or value there between). In an embodiment, the air heating
rate may be from about 0 million BTU per hour to about 4 million
BTU per hour (and any range or value there between). In an
embodiment, the water flow rate may be about 50 gallons per minute
(GPM) to about 800 GPM (and any range or value there between).
[0770] In an embodiment, the method 700 comprises a step 704 of
drawing wastewater into the system from an external water source
using a first pump and a first valve. In an embodiment, a
wastewater inlet permits connection to the external wastewater
source. The water inlet may be connected to the external wastewater
source via a hose, pipe or other means customary in the art.
[0771] In an embodiment, the method 700 comprises a step 706 of
diverting inlet wastewater or condensed water to a spray nozzle and
spraying the inlet wastewater through the spray nozzle to create
water droplets. In an embodiment, the water droplets may be sized
to create an optimal surface area for water evaporation, but large
enough to minimize passage through the pores of the demister
pads.
[0772] In an embodiment, the method 700 comprises a step 708 of
spraying the water droplets into a container of the system. In an
embodiment, the water droplets may be sprayed to a furthest point
in the container to lengthen air contact and enhance water
evaporation. In an embodiment, air may be blown counter to the
sprayed water droplets to increase air contact and improve water
evaporation.
[0773] In an embodiment, the method 700 comprises a step 710 of
collecting condensed water in the sump (bottom) of the container.
In an embodiment, un-evaporated water is condensed in a demister
element of the system and condensed water is collected in the sump
(bottom) of the container.
[0774] In an embodiment, the method 700 comprises a step 712 of
recycling the condensed water from the sump (bottom) of container
using a second pump and a second valve. In an embodiment, when the
condensed water reaches a predetermined high-water level, the
second pump draws condensed water from the sump (bottom) of the
container and the second valve diverts the condensed water to the
spray nozzle. In an embodiment, the second pump will continue
recirculating the condensed water until the condensed water in the
sump (bottom) of the container reaches a predetermined low-water
level or a predetermined maximum conductivity as measured by a
conductivity meter. In an embodiment, the first pump will draw
wastewater into the system from the external water source when the
condensed water in the sump (bottom) of the container reaches the
predetermined low-water level.
[0775] In an embodiment, the method 700 comprises a step 714 of
diverting concentrated water to a waste outlet using a third valve.
In an embodiment, when the condensed wastewater reaches a
predetermined maximum conductivity, the third valve diverts the
concentrated waste to the waste outlet. In an embodiment, a waste
outlet permits connection to an external waste disposal storage
(e.g., tank, truck, pond). The waste outlet may be connected to the
external waste disposal storage via a hose, pipe or other means
customary in the art.
[0776] In an embodiment, the method 700 may further comprise a step
716 of monitoring ambient temperature using an air temperature
sensor. In an embodiment, when the ambient temperature precludes
water evaporation, the system is shut down, as discussed below.
[0777] In an embodiment, the method 700 may further comprise a step
718 of monitoring pH of the inlet wastewater or condensed water
using a pH meter and adding acid solution to the inlet wastewater
or condensed water to maintain the pH at about 6.5 or below to
minimize calcium carbonate scaling. In an embodiment, the desired
pH of the wastewater may be above 6.5 if a scale inhibitor is added
to minimize carbonate and non-carbonate scaling.
[0778] The acid may be any suitable acid. Suitable acids include,
but are not limited to, hydrochloric acid and sulfuric acid. In an
embodiment, the acid may be hydrochloric acid (20 baume). In an
embodiment, the acid may be sulfuric acid (98%). In an embodiment,
the desired pH of the wastewater is about 6.5 or below to minimize
carbonate scaling. In an embodiment, the desired pH of the
wastewater may be above 6.5 if a scale inhibitor is added to
minimize carbonate and non-carbonate scaling. In an embodiment, the
amount of acid solution added to the wastewater varies, depending
on inlet water conditions (e.g., pH).
[0779] In an embodiment, the method 700 may further comprise the
step 720 of maintaining bactericide in inlet wastewater or
condensed water. In an embodiment, a predetermined amount of
bactericide solution may be added to the inlet wastewater or
condensed water to prevent microbial growth.
[0780] The bactericide may be any suitable bactericide. Suitable
bactericide includes, but is not limited to, bleach, bromine,
chlorine dioxide (generated), 2,2-dibromo-3-nitrilo-propionade
(DBNPA), glutaraldehyde, isothiazolin (1.5%) and ozone (generated).
In an embodiment, the bactericide may be selected from the group
consisting of bleach (12.5%), bromine, chlorine dioxide
(generated), DBNPA (20%), glutaraldehyde (50%), isothiazolin (1.5%)
and ozone (generated). In an embodiment, the desired bactericide
concentration is from about 10 ppm to about 1000 ppm (and any range
or value there between). The amount of bactericide solution added
to the wastewater varies, depending on inlet water condition.
[0781] In an embodiment, the method 700 may further comprise the
step 722 of maintaining scale inhibitor in the inlet wastewater or
condensed water. In an embodiment, a predetermined amount of scale
inhibitor solution may be added to the inlet wastewater or
condensed water to prevent scale growth.
[0782] The scale inhibitor may be any suitable scale inhibitor or
blend of scale inhibitors. Suitable scale inhibitor includes, but
is not limited to, inorganic phosphates, organophosphorous
compounds and organic polymers. In an embodiment, the scale
inhibitor may be selected from the group consisting of organic
phosphate esters, polyacrylates, phosphonates, polyacrylamides,
polycarboxylic acids, polymalates, polyphosphincocarboxylates,
polyphosphates and polyvinylsylphonates. In an embodiment, the
desired scale inhibitor concentration is from about 10 ppm to about
100 ppm (and any range or value there between). In an embodiment,
the desired scale inhibitor concentration is from about 2 ppm to
about 20 ppm (and any range or value there between). The amount of
scale inhibitor solution added to the wastewater varies, depending
on inlet water conditions.
[0783] In an embodiment, the method 700 may further comprise the
step 724 of maintaining defoamer in the inlet water or condensed
water. In an embodiment, a predetermined amount of defoamer
solution may be added to the inlet wastewater or condensed water to
prevent foam.
[0784] The defoamer may be any suitable defoamer. Suitable defoamer
includes, but is not limited to, alcohols, glycols, insoluable
oils, silicone polymers and stearates. In an embodiment, the
defoamer may be selected from the group consisting of fatty
alcohols, fatty acid esters, fluorosilicones, polyethylene glycol,
polypropylene glycol, silicone glycols and polydimethylsiloxane. In
an embodiment, the desired defoamer concentration is from about 10
ppm to about 100 ppm (and any range or value there between). In an
embodiment, the desired defoamer concentration is from about 2 ppm
to about 20 ppm (and any range or value there between). The amount
of defoamer solution added to the wastewater varies, depending on
inlet water conditions.
[0785] In an embodiment, the method 700 may further comprise a step
of 726 of automating the method 700 using a programmable logic
controller (PLC) or computing device. In an embodiment,
predetermined parameters (e.g., air flow rate, air heating rate,
maximum conductivity, maximum humidity, maximum pH, minimum air
temperature, minimum pH, water flow rate, water droplet size) are
input into the PLC or computing device.
[0786] In an embodiment, when ambient air temperature is above a
predetermined minimum air temperature, the PLC or computing device
controls the system in an "External Source" mode according to the
following circumstances: [0787] A first valve diverts suction of a
first pump to a water inlet, directing discharge of wastewater to a
spray nozzle. [0788] The first pump and the air blower and heater
system are running. [0789] The spray nozzles disperse the
wastewater into water droplets into a container. [0790] Any
un-evaporated water droplets are retained by the pores of a
demister element(s) and fall to the bottom of the container via
gravity.
[0791] In an embodiment, the PLC or computing device will monitor
pH of the inlet wastewater or condensed water via a pH meter and
automatically add acid solution to the pump discharge using an acid
metering pump in an acid conditioning system to maintain the pH at
about 6.5 pH or below to minimize calcium carbonate scaling. In an
embodiment, the PLC or computing device may add an amount of acid
solution to the pump discharge using the acid metering pump and an
acid flow meter.
[0792] In an embodiment, when condensed water in the sump (bottom)
of the container reaches a predetermined high-water level, the PLC
or computing device controls the system in a "Recycle" mode: [0793]
The first valve diverts suction of the second pump to a draw line
connected to the bottom of the container. [0794] The second valve
diverts discharge of the condensed water to the spray nozzles.
[0795] The second pump and the air blower and heater system
continue to run. [0796] The condensed water will be sprayed by the
spray nozzles into the container. [0797] Any un-evaporated water
droplets are retained by the pores of the demister element(s) and
fall to the sump (bottom) of the container via gravity. The PLC or
computing device continues to operate the system in a "Recycle"
mode until the condensed water level in the sump (bottom) of the
container is at or below a low-water level switch or until the
condensed water reaches a predetermined maximum conductivity.
[0798] In an embodiment, the PLC or computing device will monitor
pH of the inlet wastewater or condensed water via a pH meter and
automatically add acid solution to the pump discharge using an acid
metering pump in an acid conditioning system to maintain the pH at
about 6.5 pH or below to minimize calcium carbonate scaling. In an
embodiment, the desired pH of the wastewater may be above 6.5 if a
scale inhibitor is added to minimize carbonate and non-carbonate
scaling.
[0799] In an embodiment, the PLC or computing device will monitor
conductivity of the inlet wastewater or condensed water using a
conductivity meter.
[0800] In an embodiment, when the condensed water reaches a
predetermined maximum conductivity, the PLC or computing device
controls the system in a "Waste Discharge" mode according to the
following circumstances: [0801] The first valve continues to divert
suction of the second pump to a draw line connected to the bottom
of the container. [0802] The third valve diverts discharge of the
concentrated waste to a waste outlet. [0803] The second pump
continues to run; however, the air blower and heater system, and
the acid pump are shut off [0804] Neither conductivity nor pH is
being monitored. The PLC or other computing device continues to
operate the system in a "Discharge" mode until the water level in
the sump (bottom) of the container is at or below a low-water level
switch. At that point, the PLC or other computing device reverts to
operate the system in an "External Source" mode, and proceeds as
described above.
[0805] In an embodiment, when ambient air temperature reaches a
predetermined minimum air temperature, the PLC or computing device
controls the system in a "Suspend" mode according to the following
circumstances: [0806] The pump(s) and air blower and heater system
are shut off. [0807] The first valve diverts suction of the second
pump to a draw line connected to the sump (bottom) of the
container. [0808] The second valve diverts discharge of wastewater
to the spray nozzles.
[0809] In an embodiment, when ambient air temperature reaches a
level above the predetermined minimum level, the PLC or computing
device reverts to operate the system in the "External Source" mode,
and proceeds as described above.
Method of Using System for Spray Evaporation of Water Illustrating
Alternative Embodiments
First Alternative Embodiment
[0810] A flow diagram for a method 800 of using a first alternative
system for spray evaporation of water is shown in FIGS. 8A-8B. In
an embodiment, the method 800 comprises selecting predetermined
parameters (e.g., air flow rate, air heating rate, maximum
conductivity, maximum humidity, maximum pH, minimum air
temperature, minimum pH, water flow rate, water droplet size) for a
system for spray evaporation of water, drawing wastewater into the
system from an external water source using a pump, diverting the
wastewater to a spray nozzle, spraying the wastewater through the
spray nozzle to create water droplets, blowing the water droplets
and air into a container of the system using an air blower,
collecting condensed water in the sump (bottom) of the container,
recycling condensed water from the bottom of the container using
the pump, and diverting the concentrated waste to a waste outlet,
as illustrated in FIGS. 8A-8B.
[0811] In an embodiment, the method 800 comprises a step 802 of
selecting predetermined parameters (e.g., maximum conductivity,
water droplet size, air flow rate, air heating rate, water flow
rate, maximum humidity) for the system of spray evaporation of
water. In an embodiment, the maximum conductivity may be about
1,000 micro .mu.S/cm to about 400,000 .mu.S/cm (and any range or
value there between). In an embodiment, the water droplet size may
be about 50 .mu.m to about 1,000 .mu.m (and any range or value
there between). In an embodiment, the air flow rate may be about
60,000 cubic feet per minute (CFM) to about 150,000 CFM (and any
range or value there between). In an embodiment, the water flow
rate may be about 50 gallons per minute (GPM) to about 800 GPM (and
any range or value there between). In an embodiment, the water flow
rate may be about 15 GPM to about 100 GPM (and any range or value
there between).
[0812] In an embodiment, the method 800 comprises a step 804 of
drawing wastewater into the system from an external water source
using a pump. In an embodiment, a wastewater inlet permits
connection to the external wastewater source. The water inlet may
be connected to the external wastewater source via a hose, pipe or
other means customary in the art.
[0813] In an embodiment, the method 800 comprises a step 806 of
diverting inlet wastewater or condensed water to a spray nozzle
using a 3-way valve and spraying the inlet wastewater or condensed
water through the spray nozzle to create water droplets. In an
embodiment, the water droplets may be sized to create an optimal
surface area for water evaporation.
[0814] In an embodiment, the method 800 comprises a step 808 of
blowing the water droplets and air into a container of the system.
In an embodiment, the water droplets and air may be blown to a
furthest point in the container to lengthen air contact and enhance
water evaporation.
[0815] In an embodiment, the method 800 comprises a step 810 of
collecting condensed water in the sump (bottom) of the container.
In an embodiment, un-evaporated water is condensed in a demister
element of the system and condensed water is collected in the sump
(bottom) of the container.
[0816] In an embodiment, the method 800 comprises a step 812 of
recycling the condensed water from the sump (bottom) of the
container using the pump. In an embodiment, when the condensed
water reaches a predetermined high-water level, the pump draws
condensed water from the sump (bottom) of the container instead of
drawing wastewater into the system from the external water source.
In an embodiment, the pump will continue recirculating the
condensed water until the condensed water in the sump (bottom) of
the container reaches a predetermined low-water level or a
predetermined maximum conductivity as measured by a conductivity
meter. In an embodiment, the pump will draw wastewater into the
system from the external water when the condensed water in the sump
(bottom) of the container reaches the predetermined low-water
level.
[0817] In an embodiment, the method 800 comprises a step 814 of
diverting concentrated water to a waste outlet using a 3-way valve.
In an embodiment, when the condensed wastewater reaches a
predetermined maximum conductivity, a 3-way valve diverts the
concentrated waste to the waste outlet. In an embodiment, a waste
outlet permits connection to an external waste disposal storage
(e.g., tank, truck, pond). The waste outlet may be connected to the
external waste disposal storage via a hose, pipe or other means
customary in the art.
[0818] In an embodiment, the method 800 may further comprise a step
816 of monitoring weather conditions using a hygrometer. In an
embodiment, when the weather conditions (e.g., barometric pressure,
humidity, temperature) preclude water evaporation, the system is
shut down, as discussed below.
[0819] In an embodiment, the method 800 may further comprise a step
818 of monitoring pH of the inlet wastewater or condensed water
using a pH meter and adding acid solution to the inlet wastewater
or condensed water to maintain the pH at about 6.5 or below to
minimized calcium carbonate scaling. In an embodiment, the desired
pH of the wastewater may be above 6.5 if a scale inhibitor is added
to minimize carbonate and non-carbonate scaling.
[0820] The acid may be any suitable acid. Suitable acids include,
but are not limited to, hydrochloric acid and sulfuric acid. In an
embodiment, the acid may be hydrochloric acid (20 baume). In an
embodiment, the acid may be sulfuric acid (98%). In an embodiment,
the desired pH of the wastewater is about 6.5 or below to minimize
calcium carbon scaling. In an embodiment, the amount of acid
solution added to the wastewater varies, depending on inlet water
conditions (e.g., pH, alkalinity).
[0821] In an embodiment, the method 800 may further comprise the
step 820 of adding a predetermined amount of bactericide solution
to the inlet wastewater or condensed water to minimize microbial
growth.
[0822] The bactericide may be any suitable bactericide. Suitable
bactericide includes, but is not limited to, bleach, bromine,
chlorine dioxide (generated), 2,2-dibromo-3-nitrilo-propionade
(DBNPA), glutaraldehyde, isothiazolin (1.5%) and ozone (generated).
In an embodiment, the bactericide may be selected from the group
consisting of bleach (12.5%), bromine, chlorine dioxide
(generated), DBNPA (20%), glutaraldehyde (50%), isothiazolin (1.5%)
and ozone (generated). In an embodiment, the desired bactericide
concentration is from about 10 ppm to about 1000 ppm (and range or
value there between). The amount of bactericide solution added to
the wastewater varies, depending on inlet water conditions.
[0823] In an embodiment, the method 800 may further comprise a step
of 822 of automating the method 800 using a programmable logic
controller (PLC) or computing device. In an embodiment,
predetermined parameters (e.g., air flow rate, air heating rate,
maximum conductivity, maximum humidity, maximum pH, minimum air
temperature, minimum pH, water flow rate, water droplet size) are
input into the PLC or computing device.
[0824] In an embodiment, when ambient humidity is below a
predetermined maximum humidity, the PLC or computing device
controls the system in an "External Source" mode according to the
following circumstances: [0825] A first 3-way valve diverts suction
of a pump to a water inlet. [0826] A second 3-way valve diverts
discharge of wastewater to a spray nozzle. [0827] The pump and air
blower are running. [0828] The spray nozzles atomize the wastewater
into water droplets and the air blower blows the water droplets and
air into a container. [0829] Any un-evaporated water droplets are
retained by the pores of a demister element(s) and fall to the
bottom of the container via gravity.
[0830] In an embodiment, the PLC or computing device will monitor
pH of the inlet wastewater or condensed water via a pH meter and
automatically add acid solution to the pump discharge using an acid
metering pump in an acid conditioning system to maintain the pH at
about 6.5 pH or below to minimize calcium carbonate scaling. In an
embodiment, the PLC or computing device may add an amount of acid
solution to the pump discharge using the acid metering pump and an
acid flow meter.
[0831] In an embodiment, when condensed water in the sump (bottom)
of the container reaches a predetermined high-water level, the PLC
or computing device controls the system in a "Recycle" mode: [0832]
The first 3-way valve diverts suction of the pump to a draw line
connected to the bottom of the container. [0833] The second 3-way
valve continues to divert discharge of condensed water to the spray
nozzles. [0834] The pump and air blower continue to run. [0835] The
condensed water will be atomized by the spray nozzles and blown by
the air blower from the front to the back of the container
according to the predetermined parameters (e.g., water droplet
size, air flow rate). [0836] Any un-evaporated water droplets are
retained by the pores of the demister element(s) and fall to the
sump (bottom) of the container via gravity. The PLC or computing
device continues to operate the system in a "Recycle" mode until
the condensed water level in the sump (bottom) of the container is
at or below a low-water level switch or until the condensed water
reaches a predetermined maximum conductivity.
[0837] In an embodiment, the PLC or computing device will monitor
pH of the inlet wastewater or condensed water via a pH meter and
automatically add an acid solution to the pump discharge using an
acid metering pump in an acid conditioning system to maintain the
pH at about 6.5 pH or below, if required, based on waste water
quality.
[0838] In an embodiment, the PLC or computing device will monitor
conductivity of the inlet wastewater or condensed water using a
conductivity meter.
[0839] In an embodiment, when the condensed water reaches a
predetermined maximum conductivity, the PLC or computing device
controls the system in a "Waste Discharge" mode according to the
following circumstances: [0840] The first 3-way valve continues to
divert suction of the pump to a draw line connected to the bottom
of the container. [0841] The second 3-way valve diverts discharge
of the concentrated waste to a waste outlet. [0842] The pump
continues to run; however, the air blower and the acid pump are
shut off. [0843] Neither conductivity nor pH is being monitored.
The PLC or other computing device continues to operate the system
in a "Discharge" mode until the water level in the sump (bottom) of
the container is at or below a low-water level switch. At that
point, the PLC or other computing device reverts to operate the
system in an "External Source" mode, and proceeds as described
above.
[0844] In an embodiment, when ambient humidity reaches a
predetermined maximum humidity, the PLC or computing device
controls the system in a "Suspend" mode according to the following
circumstances: [0845] The pump(s) and air blower are shut off
[0846] The first 3-way valve diverts suction of the pump to a draw
line connected to the sump (bottom) of the container. [0847] The
second 3-way valve diverts discharge of wastewater to the spray
nozzles.
[0848] In an embodiment, when ambient humidity reaches a level
below the predetermined maximum level, the PLC or computing device
reverts to operate the system in the "External Source" mode, and
proceeds as described above.
Second Alternative Embodiment
[0849] A flow diagram for a method 1200 of using a second
alternative system for spray evaporation of water is shown in FIGS.
12A-12B. In an embodiment, the method 1200 comprises selecting
predetermined parameters (e.g., air flow rate, air heating rate,
ambient temperature, discharge air temperature, maximum
conductivity, maximum humidity, maximum pH, minimum air
temperature, minimum pH, total suspended solids, volatile organic
carbon (VOC), water flow rate at feed inlet, water flow rate at
discharge outlet, water droplet size) for a system for spray
evaporation of water, drawing wastewater into the system from an
external water source using a pump, diverting the wastewater to a
manifold, a drip system, a packing system or a tray system, flowing
the wastewater or water droplets over the packing system or the
tray system disposed within a container of the system, blowing air
into the container counter to flow of the wastewater or the water
droplets from the drip system using an air blower and heater
system, collecting condensed water in the sump (bottom) of the
container, recirculating condensed water from the bottom of the
container to the top of the container using the pump, and diverting
the concentrated waste to a waste outlet, as illustrated in FIGS.
12A-12B.
[0850] In an embodiment, the method 1200 comprises a step 1202 of
selecting predetermined parameters (e.g., air flow rate, air
heating rate, ambient temperature, discharge air temperature,
maximum conductivity, maximum humidity, maximum pH, minimum air
temperature, minimum pH, total suspended solids, volatile organic
carbon (VOC), water flow rate at feed inlet, water flow rate at
discharge outlet, water droplet size) for the system of spray
evaporation of water. In an embodiment, the maximum conductivity
may be about 1,000 micro .mu.S/cm to about 400,000 .mu.S/cm (and
any range or value there between). In an embodiment, the air flow
rate may be about 5,000 cubic feet per minute (CFM) to about 28,000
CFM (and any range or value there between). In an embodiment, the
air flow rate may be about 5,400 CFM.
[0851] In an embodiment, the water flow rate may be about 15
gallons per minute (GPM) to about 100 GPM (and any range or value
there between). In an embodiment, the water flow rate may be about
50 GPM at about 20 psi pressure.
[0852] In an embodiment, the method 1200 comprises a step 1204 of
drawing wastewater into the system from an external water source
using a pump. In an embodiment, a wastewater inlet permits
connection to the external wastewater source. The water inlet may
be connected to the external wastewater source via a hose, pipe or
other means customary in the art.
[0853] In an embodiment, the method 1200 comprises a step 1206 of
diverting inlet wastewater or condensed water to a manifold, a drip
system, a packing system or a tray system using a 2-way valve and
flowing the inlet wastewater or condensed water through the drip
orifice to create wastewater rivulets and/or water droplets.
[0854] In an embodiment, the method 1200 comprises a step 1208a of
flowing the wastewater and/or water droplets over a packing system
and/or a tray system disposed within a container of the system, and
a step 1208b of blowing air into the container of the system using
an air blower and heater system. In an embodiment, air may be blown
counter to the flowed water droplets to increase air contact and
improve water evaporation.
[0855] In an embodiment, the method 1200 comprises a step 1210 of
collecting condensed water in the sump (bottom) of the container.
In an embodiment, un-evaporated water is condensed in a demister
element of the system and condensed water is collected in the sump
(bottom) of the container.
[0856] In an embodiment, the method 1200 comprises a step 1212 of
recirculating the condensed water from the sump (bottom) of the
container using the pump. In an embodiment, when the condensed
water reaches a predetermined high-water level, the pump draws
condensed water from the sump (bottom) of the container instead of
drawing wastewater into the system from the external water source.
In an embodiment, the pump will continue recirculating the
condensed water until the condensed water in the sump (bottom) of
the container reaches a predetermined low-water level or a
predetermined maximum conductivity as measured by a conductivity
meter. In an embodiment, the pump will draw wastewater into the
system from the external water when the condensed water in the sump
(bottom) of the container reaches the predetermined low-water
level.
[0857] In an embodiment, the method 1200 comprises a step 1214 of
diverting concentrated water to a waste outlet using a 2-way valve.
In an embodiment, when the condensed wastewater reaches a
predetermined maximum conductivity, a 2-way valve diverts the
concentrated waste to the waste outlet. In an embodiment, a waste
outlet permits connection to an external waste disposal storage
(e.g., tank, truck, pond). (See e.g., FIGS. 10A & 10C). The
waste outlet may be connected to the external waste disposal
storage via a hose, pipe or other means customary in the art.
[0858] In an embodiment, the method 1200 may further comprise an
optional step 1216 of monitoring weather conditions using a
hygrometer. In an embodiment, when the weather conditions (e.g.,
barometric pressure, humidity, temperature) preclude water
evaporation, the system is shut down, as discussed below.
[0859] In an embodiment, the method 1200 may further comprise an
optional step 1218 of monitoring pH of the inlet wastewater or
condensed water using a pH meter and adding acid solution to the
inlet wastewater or condensed water to maintain the pH at about 6.5
or below to minimized calcium carbonate scaling. In an embodiment,
the desired pH of the wastewater may be above 6.5 if a scale
inhibitor is added to minimize carbonate and non-carbonate
scaling.
[0860] The acid may be any suitable acid. Suitable acids include,
but are not limited to, hydrochloric acid and sulfuric acid. In an
embodiment, the acid may be hydrochloric acid (20 baume). In an
embodiment, the acid may be sulfuric acid (98%). In an embodiment,
the desired pH of the wastewater is about 6.5 or below to minimize
calcium carbon scaling. In an embodiment, the amount of acid
solution added to the wastewater varies, depending on inlet water
conditions (e.g., pH, alkalinity).
[0861] In an embodiment, the method 1200 may further comprise an
optional step 1220 of adding a predetermined amount of bactericide
solution to the inlet wastewater or condensed water to minimize
microbial growth.
[0862] The bactericide may be any suitable bactericide. Suitable
bactericide includes, but is not limited to, bleach, bromine,
chlorine dioxide (generated), 2,2-dibromo-3-nitrilo-propionade
(DBNPA), glutaraldehyde, isothiazolin (1.5%) and ozone (generated).
In an embodiment, the bactericide may be selected from the group
consisting of bleach (12.5%), bromine, chlorine dioxide
(generated), DBNPA (20%), glutaraldehyde (50%), isothiazolin (1.5%)
and ozone (generated). In an embodiment, the desired bactericide
concentration is from about 10 ppm to about 1000 ppm (and range or
value there between). The amount of bactericide solution added to
the wastewater varies, depending on inlet water conditions.
[0863] In an embodiment, the method 1200 may further comprise an
optional step of 1222 of automating the method 1200 using a
programmable logic controller (PLC) or computing device. In an
embodiment, predetermined parameters (e.g., air flow rate, air
heating rate, maximum conductivity, maximum humidity, maximum pH,
minimum air temperature, minimum pH, water flow rate, water droplet
size) are input into the PLC or computing device.
[0864] In an embodiment, when ambient humidity is below a
predetermined maximum humidity, the PLC or computing device
controls the system in an "External Source" mode according to the
following circumstances: [0865] A first (shut-off) valve and a
first (feed) valve diverts suction of a pump to a water inlet.
[0866] A second (feed/recirculating) valve diverts discharge of
wastewater to a drip orifice via the pump. [0867] The pump and air
blower are running. [0868] The outlet of the drip orifice
discharges water droplets and the air blower blows the water
droplets and air into a container. [0869] Any un-evaporated water
droplets are retained by the pores of a demister element(s) and
fall to the bottom of the container via gravity.
[0870] In an embodiment, the PLC or computing device will monitor
pH of the inlet wastewater or condensed water via a pH meter and
automatically add acid solution to the pump discharge using an acid
metering pump in an acid conditioning system to maintain the pH at
about 6.5 pH or below to minimize calcium carbonate scaling. In an
embodiment, the PLC or computing device may add an amount of acid
solution to the pump discharge using the acid metering pump and an
acid flow meter.
[0871] In an embodiment, when condensed water in the sump (bottom)
of the container reaches a predetermined high-water level, the PLC
or computing device controls the system in a "Recirculation" mode:
[0872] The second (feed/recirculating) valve and the third
(recirculating) valve divert discharge of condensed water to the
drip orifice via the pump. [0873] The pump and air blower continue
to run. [0874] The condensed water will be distributed by the drip
orifice and blown by the air blower from the bottom to the top of
the container according to the predetermined parameters (e.g.,
water droplet size, air flow rate). [0875] Any un-evaporated water
droplets are retained by the pores of the demister element(s) and
fall to the sump (bottom) of the container via gravity. The PLC or
computing device continues to operate the system in a
"Recirculation" mode until the condensed water level in the sump
(bottom) of the container is at or below a low-water level switch
or until the condensed water reaches a predetermined maximum
conductivity.
[0876] In an embodiment, the PLC or computing device will monitor
pH of the inlet wastewater or condensed water via a pH meter and
automatically add an acid solution to the pump discharge using an
acid metering pump in an acid conditioning system to maintain the
pH at about 6.5 pH or below, if required, based on waste water
quality. In an embodiment, the PLC or computing device will monitor
conductivity of the inlet wastewater or condensed water using a
conductivity meter.
[0877] In an embodiment, when the condensed water reaches a
predetermined maximum conductivity, the PLC or computing device
controls the system in a "Waste Discharge" mode according to the
following circumstances: [0878] The pump, air blower and acid pump
are shut off. [0879] The fourth (discharge) valve diverts discharge
of the concentrated waste to a waste outlet. [0880] Neither
conductivity nor pH is being monitored. The PLC or other computing
device continues to operate the system in a "Waste Discharge" mode
until the water level in the sump (bottom) of the container is at
or below a low-water level switch. At that point, the PLC or other
computing device reverts to operate the system in an "External
Source" mode, and proceeds as described above.
[0881] In an embodiment, when ambient humidity reaches a
predetermined maximum humidity, the PLC or computing device
controls the system in a "Suspend" mode according to the following
circumstances: [0882] The pump and air blower are shut off. [0883]
The second (feed/recirculating) valve and the third (recirculating)
valve divert discharge of condensed water to the drip orifice via
the pump. [0884] In an embodiment, when ambient humidity reaches a
level below the predetermined maximum level, the PLC or computing
device reverts to operate the system in the "External Source" mode,
and proceeds as described above.
[0885] The embodiments set forth herein are presented to best
explain the present invention and its practical application and to
thereby enable those skilled in the art to make and utilize the
invention. However, those skilled in the art will recognize that
the foregoing description has been presented for the purpose of
illustration and example only. The description as set forth is not
intended to be exhaustive or to limit the invention to the precise
form disclosed. Many modifications and variations are possible in
light of the above teaching without departing from the spirit and
scope of the following claims. The invention is specifically
intended to be as broad as the claims below and their
equivalents.
[0886] Definitions.
[0887] As used herein, the terms "a," "an," "the," and "said" mean
one or more, unless the context dictates otherwise.
[0888] As used herein, the term "about" means the stated value plus
or minus a margin of error or plus or minus 10% if no method of
measurement is indicated.
[0889] As used herein, the term "or" means "and/or" unless
explicitly indicated to refer to alternatives only or if the
alternatives are mutually exclusive.
[0890] As used herein, the terms "comprising," "comprises," and
"comprise" are open-ended transition terms used to transition from
a subject recited before the term to one or more elements recited
after the term, where the element or elements listed after the
transition term are not necessarily the only elements that make up
the subject.
[0891] As used herein, the terms "containing," "contains," and
"contain" have the same open-ended meaning as "comprising,"
"comprises," and "comprise," provided above.
[0892] As used herein, the terms "having," "has," and "have" have
the same open-ended meaning as "comprising," "comprises," and
"comprise," provided above.
[0893] As used herein, the terms "including," "includes," and
"include" have the same open-ended meaning as "comprising,"
"comprises," and "comprise," provided above.
[0894] As used herein, the phrase "consisting of" is a closed
transition term used to transition from a subject recited before
the term to one or more material elements recited after the term,
where the material element or elements listed after the transition
term are the only material elements that make up the subject.
[0895] As used herein, the term "simultaneously" means occurring at
the same time or about the same time, including concurrently.
[0896] Incorporation By Reference. All patents and patent
applications, articles, reports, and other documents cited herein
are fully incorporated by reference to the extent they are not
inconsistent with this invention.
* * * * *